See

discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/259125073

Wear mechanisms of several cutting tool

materials in hard turning of high carbon
chromium tool steel

Article in Tribology International February 2014

DOI: 10.1016/j.triboint.2013.10.011

CITATIONS READS

25 193

6 authors, including:

Mohamed Shalaby James Krzanowski

McMaster University University of New Hampshire
12 PUBLICATIONS 77 CITATIONS 67 PUBLICATIONS 1,228 CITATIONS

SEE PROFILE SEE PROFILE

S.C. Veldhuis G.K. Dosbaeva

McMaster University McMaster University
97 PUBLICATIONS 1,512 CITATIONS 24 PUBLICATIONS 488 CITATIONS

SEE PROFILE SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Optimization of Process Parameters in Selective Laser Melting (SLM) of Aerospace Alloys View project

All content following this page was uploaded by G.K. Dosbaeva on 07 January 2015.

The user has requested enhancement of the downloaded file.

 Tribology International 70 (2014) 148154

Contents lists available at ScienceDirect

Tribology International
journal homepage: www.elsevier.com/locate/triboint

Wear mechanisms of several cutting tool materials in hard turning

of high carbonchromium tool steel
M.A. Shalaby a, M.A. El Hakim b, Magdy M. Abdelhameed b, J.E. Krzanowski c,
S.C. Veldhuis d, G.K. Dosbaeva d,n
a
Technical Research Center, Cairo, Egypt
b
Faculty of Engineering, Ain Shams University, Cairo, Egypt
c
Department of Mechanical Engineering, University of New Hampshire, Durham, USA
d
Department of Mechanical Engineering, McMaster University, Hamilton, Canada

art ic l e i nf o a b s t r a c t

Article history: The present study illustrates the performance of three different cutting tool materials, namely: PCBN, TiN
Received 31 July 2013 coated PCBN, and mixed aluminum ceramic (Al2O3 TiC) in the turning of medium hardened D2 tool
Received in revised form steel (52 HRC). Formation of CrO tribolms on the ceramic tool surface as a result of interaction with the
15 October 2013
workpiece material and environment (identied by X-ray Photoelectron Spectroscopy) leads to
Accepted 17 October 2013
Available online 24 October 2013
improvement of lubricating properties at the tool/chip interface. Obtained results revealed that the
mixed alumina ceramic tool can outperform both types of PCBN under different machinability criteria.
Keywords: Crown Copyright & 2013 Published by Elsevier Ltd. All rights reserved.
Hard turning
Tool wear
PCBN tool material
Alumina ceramic tool material

1. Introduction tool material due to a benecial combination of physical properties

Hard turning is a process of single point cutting of workpieces
that have hardness levels in the range of 4565 HRC. An example
is AISI D2 steel, which is a high carbon and chromium tool steel
alloyed with a smaller amount of molybdenum and vanadium.
This steel is characterized by a high wear resistance, and it can
be used in the medium-hardened state (5256 HRC) for deep
drawing, rolling, punching, and extrusion dies. Since the late 1970s
hard turning of hardened steels such as D2 has been technically
and economically competitive to cylindrical grinding [1]. The
major benets of hard turning compared with cylindrical grinding
come from process exibility and economy [2]. Dry, hard turning
eliminates disposal and recycling cost of coolants. It has been
found out that turned surfaces may have a fatigue life as large as
twice that of ground surfaces with equivalent surface nish [3].
Historically, the rst ceramic material used as a cutting tool for
hard turning was alumina (Al2O3). However, this material has
limited applications due to its poor fracture toughness and low
thermal conductivity. These disadvantages of alumina have been
improved by means of additives such as ZrO2, SiC, TiC and TiCN.
Nowadays, (Al2O3 TiC) mixed ceramic is widely used as a cutting
n
Corresponding author. Tel.: 1 905 525 9140.
E-mail address: jdosby@mcmaster.ca (G.K. Dosbaeva).
such as high thermal shock resistance, fracture toughness, and
high wear resistance [4]. Moreover, they are excellent materials for
high speed cutting due to their high hardness, especially at high
temperatures, and their relatively low chemical reactivity with
steels and many other materials [5]. The presence of Al2O3 in a
cutting tool assists in reducing the adhesion of the workpiece
material to the cutting tool surface, consequently increasing the
cutting tool life [6,7].
Polycrystalline cubic boron nitride (PCBN) has also been con-
sidered as a suitable choice for hard turning applications, particu-
larly those that require high accuracy and good surface nish. TiN
coatings have been used to improve performance of the PCBN [8].
In spite of the extensive work in that eld, turning of hardened
alloy steels still constitutes a challenge to the machining process,
and in particular the performance of the cutting tools. The
presence of multiple alloying elements leads to the formation of
very hard carbide particles in the structure of such steels when
heat treated, leading to excessive tool wear. The resultant cutting
tool wear plays a major role during nish hard turning due to its
effects on surface integrity and dimensional accuracy [9]. The
capability to predict tool wear during hard turning is necessary to
avoid catastrophic tool failure, which leads to damage of the
workpiece surface, destruction of the cutting tool, and may affect
machine tool performance. Moreover, it can be used to determine
the optimum cutting speed for the minimum machining cost.

0301-679X/$ - see front matter Crown Copyright & 2013 Published by Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.triboint.2013.10.011
 M.A. Shalaby et al. / Tribology International 70 (2014) 148154
Abrasive wear has been frequently reported as the main wear
mechanism in hard turning [10,11]. Due to high temperature and
high stresses in hard turning, diffusion wear also may occur and is
often accompanied by the decomposition of a component of one of
the sliding surfaces. Chemical reactions, including oxidation at
high speeds due to a high cutting temperature have also been
reported [11].
The measurement of cutting force components during hard
turning is essential to determine the torque and the power in order
to select the proper machine tool to carry out the machining process.
Moreover, the determination of the radial force component is
necessary to calculate the Machine-Fixture-Tool-Workpiece (MFTW)
system deection, which affects workpiece accuracy [12]. Cutting
forces are therefore used in the present study as a machinability
criterion to compare between the different cutting tool materials.
The present work provides a scientic approach to select the most
proper tool material for machining of the medium hardened D2 tool
steel. Three different tool materials most widely recommended by
literature [1315] for hard turning of hardened steels have been used:
low content Polycrystalline Cubic Boron Nitride, PCBN (BNX20); TiN
coated PCBN (7020) having the same chemical composition as the rst
type; and (Al2O3 TiC) mixed alumina ceramic, a chemically stable
tool material with high red hardness and reasonable toughness.
2. Experimental work
AISI D2 high carbon high chromium tool steel hardened to 52
HRC has been used in the present work. The chemical composition
of the used workpiece material is presented in Table 1. The
chemical composition and the hardness of the used tool materials
are given in Table 2. The cutting tool inserts were mounted on a
tool holder having the specications mentioned in the same table.
The tool nose radius (r) was kept constant at 1.2 mm for all the
tool materials used. Machining tests were carried out on a 3 kW
digitally controlled general purpose center lathe. A tool makers
microscope was used to measure the tool ank wear land width
(VB). Progressive ank wear has been plotted against the machin-
ing time (t), in minutes. Tool life was determined at 0.2 mm ank
wear. The scatter of tool wear measurements was around 10%.
Scanning electron microscope (SEM) was used to study the wear
mechanisms of the different cutting tools. A 3-components tool
force turning dynamometer was used for measuring the cutting
force components. The calibration of the cutting forces dynam-
ometer was carried out using a loading device with a capacity of
2000 N. The calibration procedures were repeated 3 times, and the
average least squares line has nally been used. Two cutting
speeds (vc) of 100 and 175 m/min were used. The chip was
collected at different cutting speeds and its thickness was mea-
sured using a digital micrometer to obtain the chip compression
Table 1
Chemical composition of the workpiece material.
%C %Si %Mn %Cr %Mo %V
1.55 0.3 0.4 11.8 0.8 0.8
Table 2
Chemical composition of the cutting tool materials and tool holder specications [2931].
Tool material Chemical compositions
PCBN (BNX20) 60%CBN TiN binder
TiN coated PCBN (CB7020) 57% CBN TiN binder TiN physical
vapor deposition (PVD) coated, 2 m thickness
Mixed Alumina 70% Al2O3 30% TiC
149
ratio (c). After each cutting test, the workpieces were machined
using a mixed-alumina tool at a relatively low cutting speed of
30 m/min to minimize the probable effect of tool wear on the
machined surface during the previous pass. Considering the work-
piece materials ability to harden, the machined depth of cut after
all the machining passes did not exceed 4 mm, maintaining uni-
form workpiece properties throughout the machining tests.
The characteristics of the surface tribo-lms that were formed on
the worn surface were studied using the X-ray photoelectron spectro-
scopy (XPS) on a Kratos-HS XPS system. A MgK X-ray source was
used, running at 15 kV and 10 mA. For the detailed scans on individual
elements (as shown in this work for Cr) the scan was run at a pass
energy of 160 eV, a step size of 50 meV, a dwell time of 100 ms with
10 passes. To reduce the impact of surface impurities on the nal
result, the sample was etched in the XPS system before collection of
the scan using 4 keV Ar ions for 5 min. The deconvolution analysis
was carried out using the system-supplied software and database.
3. Results
3.1. Tool wear and tool life
Fig. 1 illustrates the behavior of the tool ank wear land width
(VBB) as wear scars occurred in the tool corner area with the
machining time (t) for the three tool materials. Firstly, a machining
test was carried out at 100 m/min. It was noticed that at the
beginning of the machining process, the lowest wear was obtained
with the PCBN tool. However, after a machining time of 5.5 min,
(after exceeding a ank wear of 0.12 mm) the lowest wear was
obtained by the ceramic tool. The TiN coated PCBN gave the
highest wear value amongst the used tool materials.
When the cutting speed was increased to 175 m/min, similar
results were observed. The PCBN tool at rst displayed the lowest
wear value. However, after 4.3 min, (after reaching a ank wear
land of 0.16 mm) the ceramic tool displayed the lowest wear
values. The highest wear was obtained by the coated PCBN tool.
Fig. 1 shows that the running-in and the stable wear stages can
be easily observed when using the ceramic tool, whereas for the
two types of PCBN tool; higher ank wear values in relation to
time were obtained.
The corresponding tool life values for a ank wear land width
of 0.2 mm are given in Table 3. The mixed ceramic tool shows
2034% higher tool life than uncoated PCBN, and a 100300%
higher tool life than TiN coated PCBN at the cutting speeds
examined here. This can be attributed to the relatively lower red
hardness of TiN as a compound compared to TiC and alumina, as
clearly shown at the higher speed of 175 m/min.
Fig. 2 presents the SEM micrographs of the three worn out
inserts. The abrasion marks are clear on the three cutting tool
anks. Crater wear is not found on the ceramic tool face, whilst it
can be observed on the faces of the two types of PCBN inserts.
3.2. Chip formation
%Fe
Balance
The chip study is important for the fundamental understanding
of the entire performance of the cutting process. Chip morphology
Hardness Tool holder specications Inserts micro-geometry
31003300 HV  51 rake angle, 51 clearance Chamfer angle 251, Effective chamfer
27002900 HV angle, 751 setting angle angle 301, Cutting edge angle 901
2000 HV
150 M.A. Shalaby et al. / Tribology International 70 (2014) 148154

0.3
(mm)
0.25
Flank wear (VBB)

0.2

0.15

0.1 TiN coated PCBN (7020)

PCBN (BNX20)
0.05 Ceramic

0
0 3 6 9 12 15 (min) 18

Machining time (t)

0.3
(mm)
0.25
Flank wear (VBB)

0.2

0.15

0.1 TiN coated PCBN (7020)

PCBN (BNX20)
0.05
Creamic

0
0 2 4 6 8 (min) 10

Machining time (t)

Fig. 1. Wear curves at different cutting speeds using the different tool materials;
(a) vc 100 m/min, (b) vc 175 m/min; ap 0.06 mm, f 0.05 mm/rev, r 1.2 mm.

Table 3
Tool life values (minutes) for the used tool materials at ank wear land width of
0.2 mm.

Tool material Coated PCBN PCBN Mixed alumina

v 100 m/min 7 12 14.5

v 175 m/min 2 6 8

depends on both tool and workpiece materials. Accordingly, chips

were collected during each machining test for each tool material.
Discontinuous chips were obtained at low cutting speeds,
vc o20 m/min for ceramic and vc o 30 m/min for both coated
and uncoated PCBN. The difference of these cutting speed values
is due to the higher thermal conductivity of CBN compared to the
ceramic, leading to lower cutting temperatures.
At higher cutting speeds and consequently higher than average
chip temperature, a steady plastic ow of the workpiece material
occurs on the tool face producing continuous, tangled chips as
indicated in Fig. 3. The examination of the smoothness of the chip
underside can therefore reveal the intensity of adhesion of the
chip to the tool face; Fig. 3 shows the SEM chip micrographs. It can
be easily detected that the smoothest chip underside was obtained
with ceramic, indicating least adhesion of chip on the tool face,
followed by PCBN, and nally by the coated PCBN showing the
Fig. 2. SEM micrographs of the worn inserts; (a) mixed alumina ceramic, (b) PCBN,
most intense adhesion of the chip to the tool face. (c) TiN coated PCBN vc 100 m/min, ap 0.06 mm, f 0.05 mm/rev, r 1.2 mm.
The chip compression ratio (c) is a parameter dened as the
ratio between the deformed chip thickness to its undeformed
thickness. It can be used as a direct indication of the frictional coated PCBN, which conrms the results of the chip micrographs
behavior at the chiptool interface [16]. mentioned before. Each of the (cvc) relationships of the three
Fig. 4 shows the chip compression ratio (c) for each of the used cutting tool materials has a peak value at 30 m/min for the two
tool materials as a function of the cutting speed. It can be noticed types of PCBN, and 20 m/min for the ceramic. These peaks are
that the lowest values of the chip compression ratio are obtained caused by hot pressure welding causing a higher coefcient
with the ceramic tool, while the highest values are due to the of friction at the tool/chip interface under these cutting speeds.
 M.A. Shalaby et al. / Tribology International 70 (2014) 148154 151

Fig. 3. SEM micrographs of the produced chips using different tool materials; (a) mixed alumina ceramic, (b) PCBN, (c) TiN coated PCBN vc 100 m/min, ap 0.06 mm,
f 0.05 mm/rev, r 1.2 mm.

5 which decreases the friction coefcient at the tool/chip interface,

and consequently decreases the chip compression ratio. At higher
4.5
Chip compression ratio (c)

cutting speeds and hence higher cutting temperatures, lower

shear strength of the chip material at the chip underside is
4
achieved leading to a lower coefcient of friction. The high chip
compression ( 44), occurring in three cutting tool materials used,
3.5
can be attributed to the relatively small undeformed chip thick-
3 ness, which increases the coefcient of friction at the toolchip
TiN coated PCBN (7020) interface. The toolchip contact length (as a function of the
2.5 PCBN (BNX20) undeformed chip thickness) is considered small when compared
Ceramic to the chamfer width, which increases the effective rake angle and
2 consequently increases the coefcient of friction between the
0 40 80 120 160 (m/min) 200 chip-underside and the tool face.
Cutting speed (v)
3.3. Cutting forces
Fig. 4. Effect of the cutting speed (v) on the chip compression ratio (c). ap 0.06 mm,
f 0.05 mm/rev, r 1.2 mm.
Fig. 5 presents the effect of the cutting tool material on the
cutting force components: the radial cutting force components
For the same workpiece material, the speed at which the hot (Fy), the tangential cutting force component (Fz), and the axial
pressure welding takes place depends mainly on the thermal cutting force component (Fx). The cutting force measurements
properties of the tool material [17]. At low cutting speeds below were taken when the values of the tool ank wear land width not
the hot working temperature, the chips tend to be discontinuous, exceeded 0.05 mm to avoid or at least decrease the effect of tool
152
Value of the cutting force components (N)
220
200
180
160
140
120
100
80
60
40
20
0
Fy Fz
Cutting force components
Fig. 5. Effect of the cutting tool material on the cutting force components
vc 175 m/min, ap 0.15 mm, f 0.1 mm/rev, r 1.2 mm.
wear on the cutting force components. The lowest values of the
three cutting force components were those produced by the
ceramic tool, followed by the PCBN, while the largest force
components were obtained using the coated PCBN tool material.
As the cutting tool nose radius (r 1.2 mm) is greater than the
depth of cut, the radial cutting (Fy) force component was the
largest component in the tool material used.
3.4. Characterization of the surface tribo-lms on the worn surface
To understand the cause of better tool life of ceramic insert,
investigation of its worn surface was made. To study character-
istics of the tribolms, X-ray Photoelectron Spectroscopy (XPS)
analysis was used. Two kinds of the tribo-lm could be identied
on the worn rake surface of the tool. It was only possible to
identify the tribo-lms on the surface of a ceramic tool. All other
tools studied did not show formation of tribo-lms. Minor
amounts of TiO lms were found (Fig. 6a) that correspond to
our previously obtained results [18,19]. Signicant amount of
lubricating polyvalent chromium oxides are generated. A corre-
sponding spectrum is shown in Fig. 6b. The XPS spectra of the Cr
2p region (Fig. 6b) indicate the presence of two Cr states on the
surface of the worn ceramic insert. The tted spectrum has peaks
at 574.2 (Cr), 577.8 (CrOx) and 587.3 (CrOx). This interpretation
of chromium bonds is obtained in accordance with the data
published elsewhere [18,19]. The position of the photoelectron
lines is shifted from the binding energy for standard elements,
which indicates their partial oxidation with the formation of non-
equilibrium phases
The positions of the photoelectron lines are shifted from the
binding energies values for pure elements indicating their partial
oxidation with the formation of non-equilibrium phases that are
close to Cr 3  O phase.
4. Discussion
Three cutting tool materials used have been assessed using
different machinability criteria. Firstly, the tool wear mechanisms
have been dened. For the two types of PCBN, the abrasion wear
marks which have been identied on the tool ank are the result
of the presence of very hard carbides (such as chromium carbide)
in the microstructure of the workpiece material. The adhesive
wear has also been noticed from the adhesion marks on the chip
underside as shown in Fig. 3.
The higher chip compression ratio associated with the two
types of PCBN can be also used as an indication of the adhesive
wear mechanism when using the two types of PCBN tools. TiN
coated PCBN had a higher compression ratio and higher adhesion
M.A. Shalaby et al. / Tribology International 70 (2014) 148154
PCBN
Ti 2p
Coated
carbide
Ceramic
Ti O2
Ti Ox (458.09 eV)
(465.86 eV)
Fx
Cr O x
(587.3 eV)
Cr Ox
(577.8 eV)
Cr (574.2 eV)
Fig. 6. Photoelectron spectra of the (a) Ti 2p and (b) Cr 2p region taken from the
worn rake surface of ceramic tool.
mark density on the chip underside than the uncoated PCBN.
This observation can be attributed to the higher micro-hardness of
the uncoated PCBN compared with the coated one as shown in
Table 2.
The crater wear has only been observed on the tool faces of the
two types of PCBN, while it is not found on the ceramic tool face.
The presence of the craters while using the two types of the coated
and uncoated PCBN tools is considered an indication of diffusion
wear.
Referring to Fig. 1, both of the PCBN tools show at rst relatively
lower ank wear values vs. time compared to the ceramic tool.
Upon reaching a prescribed tool ank wear value (which is
dependent on the cutting speed), the ceramic tool wear rate then
becomes remarkably lower than that of the PCBN.
These phenomena are explained in the following way: ceramic
tool has low thermal conductivity (around 10 W/mK), with tem-
perature the thermal conductivity for ceramic tools reduces
signicantly [20] as compared to PCBN (56 W W/mK) [21]. The
produced chip is heated up rst by the deformation work done in
overcoming the shear resistance in the primary deformation zone,
which results in the shear plane temperature rise (s). The shear
plane temperature rise is a function of the power consumed in
shearing action at the shear zone and the workpiece material
properties in addition to the cutting conditions. Due the work
done in overcoming friction at the toolchip interface, an addi-
tional temperature rise occurs (f). The frictional temperature rise
is a function of the power consumed in overcoming the friction,
the workpiece material properties, the tool material properties,
the chip dimensions, and the toolchip contact length [22].
 M.A. Shalaby et al. / Tribology International 70 (2014) 148154
The average toolchip temperature (c) is therefore obtained as
follows:
c s f
The effect of the tool material thermal conductivity on the
average tool chip temperature has been investigated [17]. Fig. 7
shows that for prescribed cutting conditions and workpiece
material properties, the average toolchip temperature would
decrease with increasing the tool material thermal conductivity
(kt) due to the decrease of the frictional temperature rise. It has to
be mentioned that the tool material thermal conductivity has no
effect on the shear plane temperature rise. Therefore temperature
on the rake surface is signicantly higher on ceramic tools. This
promotes formation of protective/high temperature lubricating
oxides.
Two types of tribo-lms are forming on the surface of ceramic
tools. First one is due to chemical modication of tool material.
Our previous studies of the tribo-lms formed on the tool surface
using the Raman spectroscopy during hard turning of hardened
steel under similar conditions [23] provided some indication that
formation of the rst type of tribo-lm is based on the TiO phase,
and is due to the chemical modication of tool material (TiC
containing ceramics [18,19]). However, the machining conditions
used here are very hard and therefore TiO tribo-lms could not
efciently sustain such high temperature/heavy load conditions
[16], and as a result, rapidly wore out. This is why the XPS analysis
performed in this study (Fig. 6a) found only small amounts of
these TiO based tribo-lms.
It has been proven previously by Kramer and Suh [24] that the
solubility of iron in CBN is higher than in alumina, which can be
used to explain the occurrence of crater wear when using the
PCBN tools only, which does not occur on the ceramic tool surface.
Application of TiN coating on a PCBN insert does not result in tool
life improvement because the TiN layer has a limited oxidation
stability [25] and TiO tribo-lms formed cannot sustain harsh
operating conditions of dry hard turning. In a previous research
carried out by the co-authors [23], using the same mixed alumina
ceramic tool to machine hardened high speed steel (HSS), where
the friction surface was analyzed by Raman spectroscopy and SEM
elemental mapping, an Al2O3 tribo-lm was identied in the ank
wear region. The high temperature reached under such harsh
cutting conditions caused Al2O3 to diffuse to the tool surface to
form a protective layer. The high chemical and thermal stability of
the Al2O3 tribo-lm protects the tool substrate because it prevents
the heat generated at the tool/chip interface from entering the tool
core. Accordingly, it can be deduced that in this case, the adaptive
behavior of ceramic tools was developed by means of the ability of
the tool to generate a protective tribo-lm on frictional surfaces
due to the presence of certain elements in this tool material [19],
700
600
500
Temperature
400
300
200
100
0 incorporating thermophysical properties of the coatingchip interface. Wear
0 10 20 30 40 50
Tool material thermal conductivity (kt)
Fig. 7. Effect of tool material thermal conductivity (kt) on the different temperatures.
153
which reduces the tool wear under severe operating conditions.
As it was expected, the second type of tribo-lms forms due to the
tribo-oxidation of the workpiece material, which is sticking to the
rake surface as a result of friction at the chip/tool interface.
The XPS spectra of the Cr 2p region (Fig. 6) indicate the
presence of two Cr states on the surface of the worn ceramic
insert. The tted spectrum has peaks at 574.2 (Cr), 577.8 (CrOx)
and 587.3 (CrOx). This interpretation of chromium bonds is
obtained in accordance with the data published elsewhere
[26,27]. The position of the photoelectron lines is shifted from
the binding energy for standard elements, which indicates their
partial oxidation with the formation of non-equilibrium phases.
Formation of high temperature lubricious CrO tribolms that
are indentied by XPS (Fig. 6) results in improvement of lubricat-
ing properties at the tool/chip interface. The lowest cutting force
components have been obtained using the mixed alumina ceramic
tool as a result of the lowest coefcient of friction on the tool face,
which can be easily detected from the chip compression ratio data
and also conrmed by the examination of the chip underside using
SEM. Similar results were previously obtained for TiAlCrN PVD
coating with high Cr content [28].
5. Conclusions
The present study illustrates wear mechanisms of different tool
materials used in machining medium hardened AISI D2 tool steel.
Friction kinetics between each tool material and workpiece
material control the tool wear. Mixed alumina ceramic tool has
given longer tool life and lower cutting force components than
PCBN tools, which can be attributed to its higher chemical and
thermal stability, exhibited during hard machining of D2 tool steel
as well as due formation of high temperature lubricating CrOx
tribo-lms under operation. As shown in this research this
combination of characteristics does not exist with PCBN. The wear
mechanisms of PCBN can be considered as a combination of
abrasion, adhesion, and diffusion. TiN coating of PCBN has not
improved its performance. Ceramic tooling is considered the best
choice for machining the medium hardened D2 tool steel with
respect to the PCBN.
Acknowledgment
The authors would like to thank Dr. G. S. Fox-Rabinovich
(McMaster University) for his helpful assistance. One of the
authors (J.E. Krzanowski) gratefully acknowledges the US National
Science Foundation (grant CMMI/MCME-1031052) for partial
support of this research.
References
[1] Schwach Dale W, Guo YB. Feasibility of producing optimal surface integrity by
process design in hard turning. Mater Sci Eng 2005;A 395:11623.
[2] Huang Yong, Chou YKevin, Liang Steven Y. CBN tool wear in hard turning:
a survey on research progresses. Int J Adv Manuf Technol 2007;35:44353.
[3] Hashimoto F, Guo YB, Warren AW. Surface integrity difference between hard
turned and ground surfaces and its impact on fatigue life. Ann CIRP 2006:55/1.
[4] Ayas E, Kara A. Pressureless sintering of Al2O3TiCN composites. Key Eng
Mater 2004;264-268:84952.
[5] Cook MW, Bossom PK. Trends and recent developments in the material
manufacture and cutting tool application of polycrystalline diamond and
polycrystalline cubic boron nitride. Int J Refract Met Hard Mater 2000;18:
147152.
[6] Grzesik W, Nieslony P. Prediction of friction and heat ow in machining
60 70
2004;256:10817.
(W/mK) [7] Grzesik W. Friction behavior of heat isolating coating in machining: mechanical,
thermal and energy-based considerations. Int J Mach Tools Manuf 2003;43:
145150.
154 M.A. Shalaby et al. / Tribology International 70 (2014) 148154
[8] Poulachon G, Moisan A, Jawahir IS. Tool-wear mechanism in hard turning with
polycrystalline cubic boron nitride tool. Wear 2001;250:57686.
[9] Poulachon G, Alberta A, Schluraff M, Jawahir IS. An experimental investigation
of work material microstructure effects on white layer formation in PCBN hard
turning. Int J Mach Tools Manuf 2005;45:2118.
[10] Cora L, Gordon S, Phelan P. PCBN tool wear modes and mechanisms in nish
hard turning. Robotics Comput Integrated Manuf 2007;23:63844.
[11] Arsecularatne JA, Zhang LC, Montross C. Wear and tool life of tungsten carbide,
PCBN, PCD cutting tools. Int J Mach Tools Manuf 2006;46:48291.
[12] Kops L, Gould M, Mizrach M. Improved analysis of the workpiece accuracy in
turning, based on the emerging diameter. Trans ASME, J Eng Ind 1993;115:2537.
[13] Davies MA, Chou Y, Evans CJ. On chip morphology, tool wear and cutting
mechanics in nish hard turning. CIRP Ann Manuf Technol 1996;45:7782.
[14] Knig W, Klinger M, Link R. Machining hard materials with geometrically
dened cutting edges eld of applications and limitations. CIRP Ann Manuf
Technol 1990;39:614.
[15] Poulachon G, Moisan A, Jawahir IS. Tool-wear mechanisms in hard turning
with polycrystalline cubic boron nitride tools. Wear 2001;250:57686.
[16] Wright P, Trent E. Metal cutting. 4th ed.. Boston: Butterworth-Heinemann; 2000.
[17] Shalaby MA. An investigation into high precision turning of some alloy steels
[Ph D thesis]. Cairo, Egypt: Ain Shams University; 2011.
[18] Kovalev AI, Wainstein DL, Mishina VP, Fox-Rabinovich GS. Investigation of
atomic and electronic structure of lms generated on a cutting tool surface.
J Electron Spectrosc Related Phenom 1999:6375.
[19] Fox-Rabinovich GS, Totten GE. Self-organization during friction. Boca Raton,
NY: Taylor & Francis; 2007.
View publication stats
[20] Grzesik W. Composite layer-based analytical models for toolchip interface
temperatures in machining medium carbon steels with multi-layer coated
cutting tools. J Mater Process Technol 2006;176(1-3):10210.
[21] Liew WYH, Ngoi BKA, Lu YG. Wear characteristics of PCBN tools in the ultra-
precision machining of stainless steel at low speeds. Wear 2003;254(34):2657.
[22] Shaw MC. Metal cutting principles. Oxford: Clarendon Press; 1997.
[23] El Hakim MA, Abad MD, Abdelhameed MM, Shalaby MA, Veldhuis SC. Wear
behavior of some cutting tool materials in hard turning of HSS. Tribol Int
2011;44:117481.
[24] Kramer BM, Suh NP. Tool wear by solution: a quantitative understanding.
Trans ASME J Eng Ind 1980;102:3039.
[25] Munz W-DM. TiAlN nitride lms: a new alternative to TiN coatings. J Vac Sci
Technol 1986;A 4:271725.
[26] Tsitsumi T, Ikemoto I, Namikawa T. Bull Chem Soc Jpn 1981;54/3:913.
[27] Romand H, Robin M. Analyses 1974;4/7:308.
[28] Fox-Rabinovich GS, Yamamoto K, Veldhuis SC, Kovalev AI, Dosbaeva GK.
Tribological adaptability of TiAlCrN PVD coatings under high performance
dry machining conditions. Surf Coat Technol 2005;200:180410.
[29] Kumar AS, Durai AR, Sornakumar T. Wear behaviour of alumina based ceramic
cutting tools on machining steels. Tribol Int 2006;39:1917.
[30] Ezugwu EO, Tang SH. Surface abuse when machining cast iron (G-17) and
nickel-base superalloy (Inconel 718) with ceramic tools. J Mater Process
Technol 1995;55:638.
[31] Harris TK, Brookes EJ, Taylor CJ. The effect of temperature on the hardness of
polycrystalline cubic boron nitride cutting tool materials. Int J Refract Met
Hard Mater 2004;22:10510.