Performance evaluation of HiPIMS, S3p and CAE deposited coatings during dry turning of Dss2205

Abstract

The present study is an extension of our previous work. Performance evaluation of single-layer AlTiN coating deposited by Scalable Pulse Power Plasma (S3p) and High Power Impulse Magnetron Sputtering (HiPIMS), with multi-layer TiN/TiAlN and AlTiN/TiAlN coating deposited by Cathodic Arc Evaporation (CAE) is carried out. Taguchi’s full factorial design with L9 orthogonal array was used for machining. AlTiN (S3p) coating exhibited a tool life of 111 min, 1.5 times as much as AlTiN (HiPIMS) coating. Multi-layer coatings could not offer comparable performance with single-layer coatings. Among the multi-layer coatings’ tools having the top layer of Al performed better. Surface roughness exhibited by AlTiN (S3p) tool was 1.2 µm compared to 1.8 µm by AlTiN (HiPIMS) tools. The rate of reduction of cutting force for AlTiN (HiPIMS) and AlTiN (S3p) tools was found to be 5% and 11%, respectively. Multi-layer TiN/TiAlN-coated tool exhibited 2.5 times higher surface roughness compared to single-layer AlTiCrN coated tool. Empirical models showed predictability of 5% and 20% for cutting force and surface roughness respectively. The higher predictability range for surface roughness is due to influence of both cutting speed and feed. The developed models can be used for selection among AlTiN (S3p) and AlTiN (HiPIMS) coated tools.

Keywords:

• CAE
• DSS2205
• dry turning
• HiPIMS
• S3p

Acknowledgement

The authors would like to express gratitude to CemeCon, Germany and Balzer India for providing timely support regarding coating of cutting tools.

Ethical standard

The manuscript does not contain any clinical studies or patient data.

Disclosure statement

The authors declare that there is no conflict of interest and authors have full control of all the data included in the manuscript and the authors are agree to allow journal to review their data, if required

Additional information

Funding

This work was supported by the NEB and Department of Science and Technology (DST), Govt. of India under the Grant Ref: 11/10/2015-NEB (G)/03 Dated 27/09/2017.