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Tribology International 43 (2010) 11131121

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

Wear mechanisms of WC coated and uncoated tools in nish turning of

Inconel 718
Abhay Bhatt a, Helmi Attia a,b,, R. Vargas b, V. Thomson a
a
Department of Mechanical Engineering, McGill University, Montreal, Canada
b
Aerospace Manufacturing Technology Centre, Institute for Aerospace Research, National Research Council Canada, Montreal, Canada

a r t i c l e in fo abstract

Available online 24 December 2009 This paper presents the results of an experimental investigation on the wear mechanisms of uncoated
Keywords: tungsten carbide (WC) and coated tools (single-layer (TiAlN) PVD, and triple-layer (TiCN/Al2O3/TiN)
Wear mechanisms CVD) in oblique nish turning of Inconel 718. Tool wear rate and wear mechanisms were evaluated for
PVD/CVD coated tools cutting speeds, 50 o Vo 100 m/min, and feed rates, 0.075 o f o0.125 mm/rev, at a constant depth
Inconel 718 of cut of 0.25 mm. It was concluded that abrasive and adhesive wear were the most dominant wear
Finish turning mechanisms, controlling the deterioration and nal failure of the WC tools. While the triple layer CVD
coated tools exhibited the highest wear resistance at high cutting speeds and low feeds, uncoated tools
outperformed the single and multi-layer coated tools in the low range of cutting speeds and
intermediate feeds. The cutting tool with single-layer PVD coating outperformed the other tools at the
medium cutting speed.
Crown Copyright & 2009 Published by Elsevier Ltd. All rights reserved.

1. Introduction
Nickel-based alloys are widely used in the aerospace and nuclear
industry owing to their high-temperature mechanical properties, and
high resistance to oxidation and corrosion. Typical industrial
applications include gas turbine components, space vehicles, rocket
engines, submarines, steam power plants, and petrochemical equip-
ment. The combined effect of poor thermal properties (low thermal
conductivity and thermal diffusivity), high temperature strength,
tendency to severe work hardening, and high tool-workpiece afnity
makes this class of material very difcult to cut [14]. During the
machining of Ni-based alloys, the chips cool down as it passes along
the tool face, instead of heating up. This phenomenon is attributed to
the negative partition coefcient, which represents the percentage of
the heat generated at the toolchip interface that ows into the chip
[3]. As a result, the location of the maximum temperature shifts
towards the tool tip. This is also accompanied by a signicant
increase in the temperature level and the temperature gradient in the
tool at the cutting zone [5], leading to high tool wear.
The selection of the cutting tool material, geometry and
coating plays a signicant role in improving the machinability
of Inconel 718, from the surface integrity, productivity and
economics points of view. High speed steels and cemented-
 Corresponding author at: Aerospace Manufacturing Technology Centre,
Institute for Aerospace Research, National Research Council Canada, Montreal,
Canada. Fax: + 514 283 9662.
E-mail addresses: helmi.attia@mcgill.ca, helmi.attia@nrc.ca (H. Attia).
carbide cutting tools are widely used for intermittent and
continuous cutting operations of Ni-alloys, respectively, at cutting
speeds below 30 m/min. This speed limit is imposed by the high
temperature and stresses generated in the cutting zone [5,6]. The
dominant failure modes of carbide tools are severe ank wear and
notching at the tool nose and/or depth of cut (DOC). In order to
improve productivity by operating at higher cutting speeds,
coated cemented carbide tools are used. The use of multi-layer
(TiN/TiCN/TiN) coated carbide tools, produced by the physical
vapor deposition (PVD) method, has improved the machinability
of nickel-based alloys and opened the door to high speed
machining at cutting speeds above 50 m/min [7,8]. These coated
tools are, however, susceptible to chipping and/or fracture of the
tool edges, due to the high mechanical and thermal stresses, and
the adhesion of the chip material to the tool [7]. When Inconel
718 was turned at cutting speeds of 4575 m/min, it was
demonstrated that while TiAlN PVD-coating exhibits excellent
resistance to ank wear, nose wear and crater wear, TiN- and
TiCN-PVD coatings provide better resistance to depth of cut (DOC)
notching [9]. The results reported in [7] showed that chemical
vapor deposition (CVD) coated tool failed by severe notching wear
and ank wear when used to machine INCONEL 718. It was also
observed that the multi-layer (TiC/Al2O3/TiN) CVD coated tools
outperformed the single-layer (TiN) PVD coated tools, due to their
higher ank wear resistance. Considering the economics of
machining Inconel 718 at cutting speeds of 50100 m/min,
(TiAlN) PVD coated carbide inserts provided optimum perfor-
mance over multi-layer (Al2O3/TiC/TiCN) CVD, and multi-layer
(TiN/TiCN/TiN) CVD and PVD coated tools [10]. Machining with

0301-679X/$ - see front matter Crown Copyright & 2009 Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.triboint.2009.12.053
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1114 A. Bhatt et al. / Tribology International 43 (2010) 11131121
the single-layer TiN PVD-coated tools generally produced a better
surface nish due to the polishing action of the honed cutting
edge and the generation of a uniform nishing edge [11]. In nish
machining of Inconel 718 with PVD-coated carbide tools, the
dominant failure mode observed is nose wear, caused by the
initial ank wear, particularly at higher cutting speeds due to the
reduction in the chip-tool contact length [12].
New ceramic tool materials such as Al2O3TiC mixed ceramics,
sialon, Si3N4 ceramics, SiC whisker-reinforced Al2O3 ceramics and
cubic boron nitride (CBN) are increasingly used [13] to machine Ni-
based alloys at higher cutting speeds in the range 120300 m/min.
Turning Inconel 718 with CBN tools showed that while notching can
be signicantly reduced with the increase of the CBN content, the
adhesive wear is increased [14]. CBN tools are also sensitive to high
rates of wear by diffusion and subsequent crystal loss [13]. In addition
to the cost factor, these new materials pose serious technical
challenges to manufacturing operations. For example, despite its
superior hot hardness, sialon shows large ank wear when machining
nickel-based alloys and is more susceptible to solution wear [13].
The shape and geometry of the cutting tools also play an
important role in determining the tool life. An increase in the
included angle, for example, tends to increase the edge strength
and the toolchip contact area, resulting in lower stresses and
temperatures at the cutting edge. The variation in the approach
angle of the cutting tool insert also effects tool life through its
effect on the chip curvature and chip segmentation. When
machining nickel-based alloys, it is generally accepted that
rhomboid shaped tools generally gives poor performance, while
round and square shaped inserts improve tool life and surface
nish under similar cutting conditions [15].
Table 1
Properties of the tungsten carbide tools.
Property Type of tool
K313 (uncoated) RCMT 12 04 M0
(Tool A)
Hardness (HRA) 93
Density (g/cm3) 14.9
Tensile rupture strength, TRS 3100
(MPA)
Avg. grain size (mm) Fine ( 1 mm)
Binder 6% Co
Thickness of coating (mm)
Edge preparation Honed shaped
Rake angle (deg) 0 0
Clearance angle (deg) 7 7
Top rake angle (deg) 5 5
Table 2
Machining conditions tested.
Test no. Cutting speed (m/min) Feed (mm/rev)
1 50 0.075
2 0.1
3 0.125
4 75 0.075
5 0.1
6 0.125
7 100 0.075
8 0.1
9 0.125
The main objective of the present study is to assess the
machinability of Inconel 718 in high speed nish turning
operations using round tools, with particular interest in under-
standing the effect of cutting conditions (speed and feed) on the
tool wear mechanisms, the progression of wear with time, and the
quality of the machined surface. The performance of tool coatings,
namely, single-layer (TiAlN) PVD and triple-layer (TiCN/Al2O3/
TiN) CVD on WC substrate is assessed.
2. Experimental methodology
Inconel 718, with surface hardness around 32 HRC, was used as
the workpiece material. This hardness value falls in the range of
commonly used alloys; 250350 HV, which is equivalent to 2336
HRC [5]. To improve the machinability of Inconel 718 and to keep its
properties unchanged, independent of the product form, it is a
common practice to keep the hardness below 38 HRC for aerospace
applications [16]. The material was solution heat-treated and aged
according to the AMS standard 5662 [17]. The workpiece was
63 mm in diameter and 150 mm long. Six specimens were prepared
for the nish turning operation. Round-shaped tools (12 mm OD)
with ISO designation RCMT 1204M0 were used for all the
experiments. Three types of tungsten carbide (WC) tools were used:
(i) tool A: uncoated WC6% Co with ne grain size of 1 mm, (ii) tool
B: single-layer (TiAlN) PVD coating on WC substrate with ne grain
size of 1 mm. The thickness of the coating is 3 mm, and (iii) tool C:
triple-layer (TiCN/Al2O3/TiN) CVD coating on WC substrate with
medium grain size 41 mm. The thickness of the coating is 14.5 mm
(5/8/1.5). Additional information on the geometry and on the
KC5010 (PVD TiAlN) coated RCMT 12 KC8050 (CVD TiCN/Al203/TiN)
04 M0 (Tool B) coated RCMT 12 04 M0 (Tool C)
93 90.6
14.9 13.9
3100
Fine ( 1 mm) Medium (4 1 mm)
6% Co 7% Co
3 14.5
Honed shaped Honed shaped
0
7
5
Tool
Tool A (uncoated WC, K313),
Tool B (single-layer (TiAlN) PVD coating, KC5010, and
Tool C (triple-layer (TiCN/Al2O3/TiN) CVD coating, KC8050.
The substrate is tungsten carbide (WC), 67% Co.
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A. Bhatt et al. / Tribology International 43 (2010) 11131121 1115

mechanical properties of the tools are listed in Table 1. The tools accordance with ISO 3685 [18], using standard stereoscopic
were clamped in a standard holder (ISO designation SRGCL 2525 microscope (Nikon Model SMZ-2). The measurements were done
M12), with a rake angle of 01 and an approach angle of 451. using the xy stage attached to the base of the microscope. For tool
Finish turning operations were performed on a 2-spindle, wear measurement, the insert was not removed from the tool
6-axis CNC Turning Center (Boehringer NG200), with the following holder and was mounted at the same position after measuring the
characteristics: 36 kW spindle, maximum spindle speed of wear. Cutting tests were stopped when any of the following failure
4000 rpm, and maximum feed rate of 25 m/min. The machining criteria were reached in accordance with ISO 3685 [18]: (a)
conditions are listed in Table 2. Flank wear was measured in average ank wear VBa of 300 mm, (b) maximum ank wear VBmax

Rake Face
Rake Face
Coating

Adhesion
Abrasion

100 m 100 m

Abrasion Flank Face Flank Face

Adhesion

Coating Rake Face

Adhesion
Flaking

Abrasion Flank Face

100 m

Fig. 1. SEM images of the cutting tools at cutting speed V = 50 m/min and feed f =0.075 mm/rev: (a) rake and ank face for tool A at 33.55 min, (b) rake and ank face for tool
B at 24.34 min, and (c) rake and ank face for tool C at 2.5 min.

Ni - Material
Relative Intensity of

Relative Intensity of
No. X-Rays

No. X-Rays

W
Mo Cr Cr Ni
Ni Ni
Mo Fe
Al Fe
Nb Ti Cr
Cr Ni C Al Nb Ti Ni

Energy (KEV) Energy (KEV)

Relative Intensity of
No. X-Rays

W
Ni - Material Adhesion
Al
Ti
W Cr Fe Ni Ni

Energy (KEV)
Fig. 2. Chemical analysis of (a) the tool rake face for tool A, (b) the tool rake face for tool B, and (c) the tool rake face for tool C (V = 50 m/min, f = 0.075 mm/rev).
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1116 A. Bhatt et al. / Tribology International 43 (2010) 11131121

of 600 mm, or (c) notch wear VBN of 800 mm. The worn tools were
further analyzed using a stereoscopic microscope (Olympus Model
SZX 12), and SEM analysis. In all tests, three separate
measurements were taken on the tools ank face.
The stereoscopic microscope has been calibrated against
standard block gauges. The standard error was found to be
73.17 mm. The sources of uncertainties considered in estimating
the tool life are ank wear measurement, cutting conditions
variability (spindle speed and feed rate), and time measurement.
The uncertainty of the wear measurement that includes con-
tributions from the xy table calibration and the insert positioning
errors results in a relative standard uncertainty of o2.5%.
Following the data presented in [19] on a similar Boehringer
Turning Center, the uncertainties in the spindle cutting speed and
feed rate are assumed to be o0.5%. As for the time measurement,
its standard uncertainty is estimated to be 0.05 min. The error in
tool life measurement is estimated to be o 70.15 min.
3. Results and discussion
3.1. Tool wear mechanism at a relatively low cutting speed
(50 m/min)
Figs. 1(ac) show the SEM images for the wear mechanisms
observed at a relatively low cutting speed of 50 m/min and a feed
of 0.075 mm/rev for tools A, B and C, respectively. The wear
mechanisms observed were mainly abrasive and adhesive wear
on the tool rake face and the ank face. This applies to all three
tools. The abrasive wear is due to the presence of hard particles
and impurities within the workpiece material [5], such as carbon,
nitride, and oxide compounds, as well as, built-up fragments. The
adhesive wear is due to the high temperature and pressure during
cutting, which causes welding to occur between the clean fresh
surface of the chip and the rake face. Fig. 2 shows the X-ray
spectro-chemical analysis of the rake face of all three types of
tools, in terms of the relative intensity of the X-ray count versus
energy. The gure demonstrates the transfer of material and the
wear by adhesion. Flank wear is the common tool wear
mechanism observed for all three different types of tools.
However, as is shown in Fig. 1(c), with tool C, another tool wear
mode was observed; aking of the coating. This wear mechanism
became more evident when the test was continued after reaching
the tool wear criterion of 300 mm of average ank wear [20]. The
sharp drop in the tool life below 2.5 min is likely due to crack
initiation at the coating/substrate interface due to the formation
of Z-phase in the carbide substrate. This brittle compound, which
is formed in a carbon-depleted zone, also promotes the creation of
voids because of its high density compared to the WC from which
it is formed. The resulting loss of adhesion at the CVD coating-
substrate interface accelerates aking and loss of tool life. The
depth of cut (DOC) notch wear was seen only with tool C with

DOC Notch
1000 m 1000 m Wear

DOC Notch
Wear

Fig. 3. DOC notch wear observed on tool C at V = 50 m/min and f = 0.075 mm/rev: (a) rake face, and (b) ank face.

Rake Face

Adhesion

Abrasion

Flank Face
100 m 100 m

Rake Face
Flaking
Adhesion
Abrasion

100 m Flank Face

Fig. 4. SEM images of the cutting tools at cutting speed V =50 m/min and feed f = 0.1 mm/rev: (a) rake and ank face for tool A at 38.85 min, (b) rake and ank face for tool B
at 19.75 min, and (c) rake and ank face for tool C at 11.60 min.
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A. Bhatt et al. / Tribology International 43 (2010) 11131121 1117

CVD triple-layer coating (TiCN/Al2O3/TiN), as illustrated in Fig. 3.
However, this is not a dominant tool failure mode. The wear
mechanisms were also studied with different feeds of 0.1 and
0.125 mm/rev at the same cutting speed of 50 m/min. As
illustrated in Figs. 4 and 5, no signicant difference exists in the
tool wear mechanisms when the feed rate is increased. The effect
of feed on the tool life, which corresponds to an average ank
wear of 300 mm, is presented in Fig. 6 for V= 50 m/min. At this
relatively low cutting speed, tool A outperforms tools B and C. The
good performance of the ne-grained uncoated low-cobalt
content tool material can be attributed to the exceptional edge
wear-resistance, high strength, and resistance to deformation and
depth of cut notch wear. These properties are adequate to endure
the thermal and mechanical stresses produced in machining
Inconel 718 at this relatively low cutting speed, without suffering
the inherent limitations of the PVD coating (e.g., low adhesion and
residual stresses on sharp edges that can induce coating
delamination) and the CVD coating process (e.g., formation
of Z-phase, embrittlement, and the development of residual
tensile stresses). The combination of the high strength and work
hardening of Inconel 718 and the abrasive action of the hard
particles contained in the chips are responsible for the DOC
notching of the multi-layer CVD coated tool [7,13]. Severe
notching of the cutting tool has also been reported to occur
when machining nickel-based alloys even under low speed
conditions [5].
3.2. Tool wear mechanism at a medium cutting speed (75 m/min)
The wear mechanism was also studied at a medium speed
V= 75 m/min. Similar to the discussion presented in Section 3.1,
three different feeds of 0.075, 0.1 and 0.125 mm/rev were used.
Fig. 7 shows the SEM images for the wear mechanisms of the
three different types of tools used at V= 75 m/min and
f= 0.075 mm/rev. Under these conditions, the tool life for tools A,
B and C was 8.56 13.91 and 10.39 min, respectively. The wear
mechanisms seen for all three different types of tools were similar
to those observed at V= 50 m/min and a feed of 0.075 mm/rev.
However, with the tool C, another wear mechanism was seen;
namely, diffusion wear, and the tool failure mode was crater wear.
Also, excessive chipping of the cutting edge was observed, which
may be due to the observed increase in vibration level, possibly
due to the tangling of the chips. As well, a similar observation can

Rake Face

Adhesion

Abrasion

Flank Face 100 m

100 m

Rake Face

Adhesion
Flaking
Abrasion

100 m
Flank Face

Fig. 5. SEM images of the cutting tools at cutting speed V =50 m/min and feed f= 0.125 mm/rev: (a) rake and ank face for tool A at 27.42 min, (b) rake and ank face for tool
B at 20.32, and (c) rake and ank face for tool C at 8.19 min.

50
Tool A Tool B Tool C
40
Tool Life (min)

30

20

10

0
0.075 0.1 0.125
Feed (mm/rev)

Fig. 6. Tool life at a relatively low cutting speed of 50 m/min.

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1118 A. Bhatt et al. / Tribology International 43 (2010) 11131121
be made as the feed increases from 0.1 to 0.125 mm/rev. However,
with an increase in feed, crater wear was not seen in the tool C,
possibly due to the presence of (Al2O3) coating layer, which has
good chemical stability at elevated temperatures [11]. Figs. 8 a
nd 9 illustrate the SEM images for all three different types of tools
at feeds f= 0.1 and 0.125 mm/rev, respectively.
The effect of feed on the tool life, determined when the average
ank wear reaches 300 mm, is presented in Fig. 10. At the medium
cutting speed of 75 m/min, tool B (single-layer TiAlN PVD coating)
outperforms the other tools A and C. As expected, the uncoated
cemented carbide tool was not well suited for high speed machining
of nickel-based alloys, due to the thermal softening of the cobalt
binder phase and the subsequent plastic deformation of the cutting
edge [21]. However, the TiAlN coating produced by the PVD process
was adequately capable of withstanding the levels of temperature
and stresses produced at this cutting speed of 75 m/min and feed
rate in the range of 0.0751.25 mm/rev. When exposed to heat, the
Rake Face
Adhesion
Abrasion
Flank Face
100 m
Coating
Adhesion
Chipping
200 m
Fig. 7. SEM images of the cutting tools at cutting speed V= 75 m/min and feed f = 0.075 mm/rev: (a) rake and ank face for tool A at 8.56 min, (b) rake and ank face for tool
B at 13.91 min, and (c) rake and ank face for tool C at 10.39 min.
Rake Face
Adhesion
Abrasion
Flank Face
100 m
Coating
100 m
Fig. 8. SEM images of the cutting tools at cutting speed V = 75 m/min and feed f = 0.1 mm/rev: (a) rake and ank face for tool A at 6.67 min, (b) rake and ank face for tool B
at 13.63 min, and (c) rake and ank face for tool C at 6.34 min.
aluminum is extracted from the lattice of TiAlN to react with air to
form a passive and chemically stable oxide layer of Al2O3. The
performance of this protective layer is further enhanced by the high
hot hardness and oxidation resistance properties (due to the
formation of an intermediate layer comprised of titanium,
aluminum, oxygen, and nitrogen during machining) [9]. Another
factor that may contribute to the high performance of the TiAlN
coating is the presence of compressive residual stresses and their
benecial ability in retarding abrasive wear and DOC notching.
The improved resistance to the abrasive wear and the relatively
low thermal conductivity of TiAlN also reduce the tendency for
cratering wear. Additionally, the ne-grained K5010 grade of the WC
substrate used in tool B, with only 6% binder, offers excellent
deformation resistance. As indicated earlier, unlike the PVD process,
the CVD coating process may reduce the fracture strength of the tool
material under some operating conditions due to interfacial Z-phase
formation or the presence of grown-in cracks due to tensile residual
Coating
100 m
Rake Face
Crater
Abrasion
Flank Face
Coating
100 m
Rake Face
Adhesion
Abrasion
Flank Face
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A. Bhatt et al. / Tribology International 43 (2010) 11131121 1119

Rake Face Coating

Adhesion

Abrasion

Flank Face
100 m 100 m

Rake Face
Coating
Adhesion

Abrasion

Flank Face
100 m

Fig. 9. SEM images of the cutting tools at cutting speed V = 75 m/min and feed f = 0.125 mm/rev: (a) rake and ank face tool A at 5.94 min, (b) rake and ank face for tool B at
8.31 min, and (c) rake and ank face for tool C at 8.61 min.

20
Tool A Tool B Tool C

15
Tool Life (min)

10

0
0.075 0.1 0.125
Feed (mm/rev)
Fig. 10. Tool life at a medium cutting speed of 75 m/min.

Rake Face Coating

Adhesion

Chipping
Abrasion

100 m Flank Face 100 m

Rake Face

Crater
Adhesion

Abrasion
100 m Flank Face

Fig. 11. SEM images of the cutting tools at cutting speed V= 100 m/min and feed f = 0.075 mm/rev: (a) rake and ank face for tool A at 2.18 min, (b) rake and ank face for
tool B at 7.57 min, and (c) rake and ank face for tool C at 8.83 min.
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stresses in the coating. This explains the lower performance of tool C
relative to tool B at the medium cutting speed.
3.3. Tool wear mechanism at a high cutting speed (100 m/min)
The wear mechanisms were also investigated at a high
cutting speed of 100 m/min for different feeds f=0.075, 0.1, and
0.125 mm/rev, respectively. The results are shown in Figs. 1113,
respectively. As expected, the tool wear rate was highly inuenced
by the cutting speed. Again, the mechanisms observed with all
three different types of tools are abrasive and adhesive wear.
Similar to the earlier observations at lower cutting speeds, the
main tool failure mode was ank wear. However, with tool B,
chipping was observed. This is due to the tangling of the chips,
which caused an increase in the vibration level. Also, with tool C, a
crater wear is observed due to the diffusion wear mechanism.
The effect of feed on the tool life, determined when the average
ank wear reaches 300 mm, at V= 100 m/min is presented in
Fig. 14. At this relatively high cutting speed, tool C outperforms
the other tools A and B. The explanation for the high performance
of the 14.5 mm thick triple-layer (TiCN/Al2O3/TiN) CVD coating can
be attributed to the following factors. First, the CVD process
creates a diffusion-type bond between the coating and the sub-
strate which is much stronger than the bond created through the
PVD process [22]. Second, multi-layering of the coating acts as a
barrier against crack propagation, when fatigue stresses are
created by the frequent formation and removal of the chip
material that adheres to the tool. These multi-layers also offer
multi-functions to the cutting tool, namely, lower friction at the
top layer (TiN), thermal protection by intermediate layer (Al2O3),
and higher wear resistance and stronger adhesion to the substrate
by the innermost layer (TiCN). Such tailored performance cannot
be achieved by a single PVD coating. Third, the thickness of the

Rake Face
Coating
Adhesion

Abrasion

Flank Face
100 m 100 m

Coating Rake Face

Adhesion
Abrasion

200 m Flank Face

Fig. 12. SEM images of the cutting tools at cutting speed V =100 m/min and feed f = 0.1 mm/rev: (a) rake and ank face for tool A at 1.98 min, (b) rake and ank face tool B at
6.51 min, and (c) rake and ank face for tool C at 8.41 min.

Rake Face

Adhesion Coating

Abrasion

100 m Flank Face 100 m

Rake Face

Crater
Adhesion
Abrasion

100 m Flank Face

Fig. 13. SEM images of the cutting tools at cutting speed V = 100 m/min and feed f= 0.1 mm/rev: (a) rake and ank face for tool A at 1.56 min, (b) rake and ank face for tool
B at 3.80 min, and (c) rake and ank face for tool C at 7.64 min.
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A. Bhatt et al. / Tribology International 43 (2010) 11131121
10
Tool A
7.5
Tool Life (min)
5
2.5
0
0.075
Feed (mm/rev)
Fig. 14. Tool Life at a high cutting speed of 100 m/min.
multi-layered coating on tool C is nearly ve times that of the PVD
coating on tool B. This improves the wear resistance without
suffering the delamination of the entire coating, as usually
experienced with thick PVD coatings.
4. Conclusions
The wear mechanisms for uncoated and coated carbide tools
(WC) were investigated. Three tools were used during the course of
investigations. It was found that abrasive and adhesive wear were
the most dominant wear mechanisms, controlling the deterioration
and nal failure of the WC tools. It was found that the triple-layer
(TiCN/Al203/TiN) CVD coating exhibits the highest wear resistance at
high speeds of 100 m/min and low feeds, whereas the uncoated WC
tool provided the best performance in the relatively low range of
cutting speeds (V=50 m/min) and intermediate feeds. The tool with
single-layer (TiAlN) PVD coating outperformed the other tools at the
medium cutting speed of 75 m/min.
Acknowledgments
This work was conducted under the partial nancial support of the
Natural Sciences and Engineering Research Council of Canada (NSERC),
which the authors greatly appreciate. The work was carried out using
the unique facilities of the Aerospace Manufacturing Technology
Centre (AMTC), Institute for Aerospace Research (IAR), National
Research Council Canada (NRC), which the authors greatly appreciate.
The authors are also grateful to Mr. Danen Challen for his technical
help and support on the performance of the machining tests.
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