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  1. 1. Contents 1.ABSTRACT.................................................................................................................................................2 4.INTRODUCTION........................................................................................................................................2 5.LITERATURE REVIEW.................................................................................................................................2 6.EXPERIMENTAL DETAILS...........................................................................................................................2 7.RESULTS....................................................................................................................................................3 COATING ROUGHNESS.............................................................................................................................3 SCRATCH TEST..........................................................................................................................................4 Critical load..........................................................................................................................................6 MICROHARDNESS....................................................................................................................................6 .....................................................................................................................................................................6 PIN ON DISC ............................................................................................................................................7 .....................................................................................................................................................................8 μ versus conditions..............................................................................................................................9 Wear coefficient versus conditions due to carbide ball......................................................................9 Wear coefficient versus conditions due to steel ball........................................................................10 CUTTING FORCE.....................................................................................................................................11 Px Versus Vc.......................................................................................................................................11 Pz Versus Vc.......................................................................................................................................14 ...............................................................................................................................................................14 ζVersus Vc..........................................................................................................................................17 F/N Versus Vc....................................................................................................................................20 TOOL WEAR TEST...................................................................................................................................23 30 seconds........................................................................................................................................23 1 min......................................................................................................................................................23 Figure 36 1 min..................................................................................................................................24 1.5 min..................................................................................................................................................24 2 min..................................................................................................................................................26 4 min..................................................................................................................................................27 CUTTING VELOCITY = 151 m/min...........................................................................................................29
  2. 2. CUTTING VELOCITY = 196m/min ..................................................................................30 .................................................................................................................30 4.. 1. ABSTRACT 2. The use of coated tools is firmly established in today's metal cutting industry. Layers of wear-resistant materials only microns thick are deposited onto conventional tool substrates to bring about significant improvements in tool performance and cutting economies through lower tool wear, reduced cutting forces and better surface finish of the workpiece Such coatings have also extended the range of workpiece materials and cutting conditions under which conventional tools are able to machine. 3. Although coated tools have been in commercial use for three decades, much is still unknown about the behaviour of these tools throughout their recommended range of machining conditions. While it is commonly acknowledged that coatings increase wear resistance, reports of the extent of the improvement differ widely 4. INTRODUCTION 5. LITERATURE REVIEW 6. EXPERIMENTAL DETAILS
  3. 3. 7. RESULTS COATING ROUGHNESS Figure 1 Coating Roughness
  4. 4. SCRATCH TEST Figure 2 Old magnetron -45V Figure 3 Old Magnetron -60V
  5. 5. Figure 4 New Magnetron -45V Figure 5 New Magnetron -60V
  6. 6. Critical load Figure 6 Critical Load MICROHARDNESS Figure 7 Microhardness
  7. 7. PIN ON DISC Ti Current N2 flow Ar flow Bias Temperature Pressure Figure 8 Old Magnetron -45V Ti Current N2 flow Ar flow Bias Temperature Pressure Figure 9 Old Magnetron -60V
  8. 8. Ti Current N2 flow Ar flow Bias Temperature Pressure Figure 10 New Magnetron -45V Ti Current N2 flow Ar flow Bias Temperature Pressure Figure 11 New Magnetron -60V
  9. 9. μ versus conditions Figure 12 sliding coefficient of friction versus conditions Wear coefficient versus conditions due to carbide ball Figure 13 Wear coefficient versus conditions due to carbide ball
  10. 10. Wear coefficient versus conditions due to steel ball Figure 14 Wear coefficient versus conditions due to steel ball
  11. 11. CUTTING FORCE Px Versus Vc Figure 15 Old Magnetron -45V Figure 16 Old Magnetron -60V
  12. 12. Figure 17 New Magnetron -45V Figure 18 New Magnetron -60V
  13. 13. Figure 19 Uncoated
  14. 14. Pz Versus Vc Figure 20 Old Magnetron -45 V Figure 21 Old Magnetron -60 V
  15. 15. Figure 22 New Magnetron -45 V Figure 23 New Magnetron -60 V
  16. 16. Figure 24 Uncoated
  17. 17. ζVersus Vc Figure 25 Old Magnetron -45V Figure 26 Old Magnetron -60 V
  18. 18. Figure 27 New Magnetron -45V Figure 28 New Magnetron -45V
  19. 19. Figure 29 Uncoated
  20. 20. F/N Versus Vc Figure 30 Old Magnetron -45V Figure 31 Old Magnetron -60V
  21. 21. Figure 32 New Magnetron -45V Figure 33 New Magnetron -60V
  22. 22. Figure 34 Uncoated
  23. 23. TOOL WEAR TEST CRATER FLANK OLD -45 CRATER FLANK OLD -45 OLD -60 Figure 35 30 seconds OLD -60 NEW-45 NEW-45 NEW-60 NEW-60 UNCOATED UNCOATED 30 seconds Figure 35 30 seconds 1 min
  24. 24. Figure 36 1 min 1.5 min Figure 37 1.5 min
  25. 25. CRATER FLANK OLD -45 OLD -60 NEW-45 NEW-60
  26. 26. 2 min CRATER FLANK OLD -45 OLD -60 NEW-45 NEW-60 Figure 38 2 min
  27. 27. 4 min CRATER FLANK OLD -45 OLD -60 NEW-45 NEW-60 Figure 39 4 min
  28. 28. Figure 40 Tool wear
  29. 29. CUTTING VELOCITY = 151 m/min OLD -45 0.08 0.12 0.16 0.20 OLD -45 OLD -60 OLD -60 NEW-45 NEW-45 NEW-60 NEW-60 UNCOATED UNCOATED 0.08 0.12 0.16 0.20
  30. 30. CUTTING VELOCITY = 196m/min

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