Impact of processing conditions on wear of contact areas and performance of carbide tools with wear-resistant coatings

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Abstract

The use of wear-resistant coatings on tool contact areas is one of the most effective methods to enhance their durability and operational stability. However, when machining hard-to-cut materials, the effectiveness of such coatings decreases significantly, making it crucial to obtain new data on their failure mechanisms and develop improved coating compositions. This study investigates the influence of processing conditions, properties of the workpiece material, and the composition of wear-resistant coatings on the wear of contact areas and the performance of carbide tools. Single-layer TiN, TiZrN, and TiSiN coatings were examined, with an evaluation of their stress state and cyclic crack resistance. The contact areas of carbide inserts were studied using optical methods, and wear tests were conducted during turning with specialized equipment. It was demonstrated that both the type of workpiece material and the cutting conditions significantly affect the coating failure mode and tool life. The advantage of binary coatings, which possess enhanced mechanical properties and pronounced compressive residual stresses, was established. This contributes to increased cyclic crack resistance and improved fracture resistance. The obtained results can be used in developing technological processes for the finish machining of hard-to-cut materials, especially under minimum quantity lubrication (MQL) conditions or complete absence of cutting fluids.

About the authors

Vladimir P. Tabakov

Ulyanovsk State Technical University

Email: vpt@ulstu.ru
ORCID iD: 0000-0002-2568-9401

Doctor of Sciences (Engineering), Professor

Russian Federation, 432027, Russia, Ulyanovsk, Severny Venets Street, 32

Oleg I. Morozov

Ulyanovsk State Technical University;
National Research University of Electronic Technology (MIET)

Author for correspondence.
Email: oi.morozov@ulstu.ru
ORCID iD: 0000-0001-8241-2591

PhD (Engineering), Associate Professor

Russian Federation, 432027, Russia, Ulyanovsk, Severny Venets Street, 32; 124498, Russia, Moscow, Zelenograd, Shokin Square, 1

Renat U. Kamenov

Togliatti State University;
National Research University of Electronic Technology (MIET)

Email: Renatkamenov@mail.ru
ORCID iD: 0000-0001-9181-5704

PhD (Engineering)

Russian Federation, 445020, Russia, Togliatti, Belorusskaya Street, 14; 124498, Russia, Moscow, Zelenograd, Shokin Square, 1

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