MICRO-MELT T15 PLUS

In the field of mechanical engineering, engineers are always looking for ways to improve the properties of materials. Cryogenic treatment of tooling steels is a proven technology to increase wear resistance and extend intervals between component replacements. The main idea of this paper is to apply Taguchi method to optimize cutting parameters in turning operation using cryogenic treated (CT) and untreated (UT) high speed steel (HSS) tools, so that the scope of cryogenic treatment on HSS tool material may be presented for the benefit of medium and small scale industry using HSS tools for cutting operation. Taguchi L25 orthogonal array is employed to study the performance characteristics in turning operations of AISI 1020 steel bars using CT and UT HSS tools. The microstructure has been found more refined and uniformly distributed after cryogenic treatment of HSS tool. It has been observed that optimum machining parameters in both the cases (CT HSS and UT HSS tools) are higher cutting speed (49.9 to 75.7 m/min.), lower feed rate (0.15 mm/rev.), medium depth of cut (0.40 mm). Analysis of variance (ANOVA) indicates that the cutting speed is most significant parameter followed by feed rate in case of CT HSS tool and depth of cut in case of UT HSS tool.

Tool materials have to fulfil a very wide range of duties and in consequence a large variety of steels have been developed. The composition and properties of high-speed, hot-work, cold-work, and other specialized tool steels are reviewed in relation to their respective fields of application. The desire for increased efficiency both in tool manufacture and in use in high-output operations has led to heavy demands upon the steel producer for improved and more consistent quality. Steelmaking and process developments in response to this challenge are outlined and the contribution that particle metallurgy techniques can make in the future is discussed. In view of the high cost and strategic vulnerability of the alloying elements used in high-speed steels and many tool steels mention ismade of the possible scope for steels of lower alloy content and for the use of composite materials or coatings.

Micro-Melt 23 is a general-purpose alloy with a good combination of properties. This high-speed tool steel is made from powder with all its inherent values. This datasheet provides information on composition, physical properties, hardness, and elasticity. It also includes information on corrosion and wear resistance as well as forming, heat treating, machining, and powder metal forms. Filing Code: TS-627. Producer or source: Carpenter Powder Technologies.

This article discusses the classifications of high-speed tool steels and describes alloying elements and their effects on the properties of high-speed tool steels. It analyzes the heat treatment of high-speed tool steels, namely, preheating, austenitizing, quenching, and tempering. Surface treatments for the high-speed tool steels are reviewed. The article emphasizes the properties and applications of high-speed tool steels and provides information on the factors in selecting high-speed tool steels.

TATMO-V is a high-speed tool steel with superior abrasion resistance because of its high contents of carbon and vanadium. It is an excellent choice for premium grade tools which require an outstanding balance of red hardness, edge toughness, and wear resistance. Increased tool life of Tatmo-V is noted in the machining of semi-hard, heat-treated steel pats (300-350 Brinell). This datasheet provides information on composition, physical properties, hardness, and elasticity as well as fracture toughness. It also includes information on forming, heat treating, and machining. Filing Code: TS-434. Producer or source: Latrobe Steel Company.

In this study, a cutting tool is developed from duplex stainless steel (DSS) using the superplastic boronizing technique. The feasibility of the development process is studied, and the cutting performances of the cutting tool are evaluated and compared with commercially available carbide and high-speed steel (HSS) tools. The superplastically boronized (SPB) cutting tool yielded a dense boronized layer of 50.5 µm with a surface hardness of 3956 HV. A coefficient of friction value of 0.62 is obtained, which is lower than 1.02 and 0.8 of the carbide and HSS tools. When tested on an aluminum 6061 surface under dry condition, the SPB cutting tool is also able to produce turning finishing below 0.4 µm, beyond the travel distance of 3000 m, which is comparable to the carbide tool, but produces much better results than HSS tool. Through superplastic boronizing of DSS, it is possible to produce a high-quality metal-based cutting tool that is comparable to the conventional carbide tool.

Structure and adhesive properties of TiN films reactively deposited by plasma-free sputtering

Manufacturing industries are presently using many tool materials, such as high speed steel, carbide tool and diamond tools etc. The most widely and commonly used tool in the engineering industries is high speed steel (HSS). The HSS tools are the cheapest and reliable for medium and small scale industries. In this work, the HSS single point cutting tool is taken as substrate material and coated with two different combinations of TiAlN composite coating using Physical vapour deposition (PVD) technique. Also, Tool life was calculated and compared with uncoated HSS tool. The hardness and surface roughness value for both the tools have been taken under same condition. The loss of weight in the tool after machining has been weighed using standard equipments. The differences have been closely observed with sufficient trials and find out the loss in weight in both the tools. The weight loss percentage was calculated after proper machining trials. The tool life of the Titanium Aluminium Nitride (Ti 70%, Al 25%) coated tool has been increased by 3.74 times than that of uncoated tool. The surface finish for TiAlN (Ti 70%, Al 25%) coating is better than the uncoated tool. The PVD coated tools having better performance comparing with uncoated HSS tool.

The electrochemical polishing behaviour of P/M high-speed steel (ASP 23) in perchloric–acetic mixed acids

High-speed steel (HSS) tools account for 20 percent of the cutting tools materials’ global market. This is due to both their significant toughness and resistance to cracking, compared to cemented carbides. Covering steel tools with hard coatings clearly improves their mechanical properties, wear resistance, and significantly increases their durability. Physical vapor deposition methods are preferred for coating metal substrates, as they allow low temperature deposition. The most widely deposited coating materials are carbides, nitrides, and borides. They are combined with softer ones in the multilayer structure to promote increased resistance to cracking and delamination in comparison to monolayered structures. In this paper, the M2 steel end mills were coated by (TiBx/TiSiyCz) x3 multilayer by the pulsed laser deposition method. Coated and uncoated tools were tested in the cylindrical down milling of AISI 316L steel. Components of the cutting force and temperature generated in the machined area during dry milling were measured under two variants of operating conditions: V1 and V2. Tool wear mechanism was examined using scanning electron microscopy (SEM), accompanied by EDS analysis of worn areas. It was found that milling with higher speed (variant V2) is accompanied by lower cutting force components and a lower temperature generated in cutting area. The presence of the coating allowed lower cutting forces and temperature in the case of variant V1. The temperature measured during milling did not exceed 200 °C. The SEM observation of the edges of cutting tools indicated that the main mechanism of wear for both types of tools was abrasion. The built-up edge formation was observed in the case of tools tested at the V1 cutting parameters variant. It was assumed that it was the reason for higher cutting forces measured during milling according to this variant. The chemical composition of built-up edges was different for coated and uncoated tools. Tribo-chemical reactions were responsible for the reduction of the cutting force and temperature components observed during milling with a coated tool at V1 variant. Boron and titanium were the elements of the coating that enabled the tribo-oxidation reactions thanks to which friction was reduced. Our results show that this beneficial effect occurs with (TiBx/TiSiyCz) x3 coated tools, but can easily be lost with inadequately selected cutting parameters.

The elemental composition, the phase composition, and the particle size of the powder fabricated by electroerosion dispersion of the waste of high-speed R18 tool steel in distilled water are investigated.

We report a new industrial application of aluminum magnesium boride AlMgB14 (BAM) coatings to enhance the hardness of tungsten carbide ceramic (WC-Co) and high-speed steel tools. BAM films were deposited by RF magnetron sputtering of a single dense stoichiometric ceramic target onto commercial WC-Co turning inserts and R6M5 steel drill bits. High target sputtering power and sufficiently short target-to-substrate distance were found to be critical processing conditions. Very smooth (6.6 nm RMS surface roughness onto Si wafers) and hard AlMgB14 coatings enhance the hardness of WC-Co inserts and high-speed R6M5 steel by a factor of two and three, respectively. Complete coating spallation failure occurred at a scratch adhesion strength of 18 N. High work of adhesion and low friction coefficient, estimated for BAM onto drill bits, was as high as 64 J/m2 and as low as 0.07, respectively, more than twice the surpass characteristics of N-doped diamond-like carbon (DLC) films deposited onto nitride high-speed W6Mo5Cr4V2 steel.

- This paper presents a comprehensive literature review and finite element analysis (FEA) of chip formation in metal cutting using Abaqus, comparing soft high-speed steel (HSS) tools and hard tungsten-carbide (WC) tools across various workpiece materials. Soft HSS tools are analyzed for difficult-to-machine alloys, including cast iron, titanium alloys, high-carbon steel, and hardened steel, while hard WC tools are analyzed for soft non-ferrous metals, such as aluminium, copper, zinc, and lead. Key machining parameters—cutting speed, feed, cutting temperature, chip morphology, and lubrication type—are summarized. The study highlights the effects of tool hardness and workpiece material on chip formation, cutting-zone temperature, and tool life, providing guidance for literature-based FEA modeling and future experimental validation. Key Words - Chip formation, Finite Element Analysis (FEA), Abaqus, HSS Tool, Tungsten-Carbide (WC) Tool, Aluminium, Copper, Zinc, Lead, Cast Iron, Titanium Alloy, Steel, Machining Parameters.

High Speed Steel (HSS) tool is commonly used in engineering applications, especially as cutters. The shortfall of this materials are wear and corrosion. However, these can be reduced by coating the surface of the material. Therefore, the purpose of this research is to investigate the effects of Diamond Like Carbon (DLC) coating, quenching heating treatment, and tempering on the physical and mechanical properties of HSS surface. The physical characteristics which will be investigated is the micro structure, while the mechanical characteristics are hardness, wear and corrosion rate. HSS has variations in their chemical composition (% mass): 0.75–1.5 C, Co >12, V > 5, 4–4.5 Cr,10–20 W and Mo. Furthermore, DLC coating uses Plasma Assisted Chemical Vapor Deposition (PACVD) technique with variation in the duration of coating (1,2,3,4,5 and 6 hours) at temperature of 300℃, with pressure variations of 1.0, 1.2, 1.4, 1.6, 1.8 and 2.0 millibar. DLC coating material be treated from methane or ethane gas, which is streamed into the fire with Argon (Ar). The result shows variations in DLC coating and the hardness grade depends on the coating time and pressure variation. DLC coating for a duration of 4 hours under 1.8 mbar pressure can reduce the surface hardness of HSS tool by 62% accompanied by increased ductility.

To minimize the manufacturing costs of parts with specified operational properties, the machining processes must be optimized. Cutting accounts for at least 70% of such processes. To that end, tool materials with distinctive properties may be developed and utilized. Analysis of manufacturing components—in particular, power components in gas-turbine engines—shows the need for higher quality of the machined surfaces and more efficient use of expensive equipment with numerical and adaptive control systems, so as to ensure a wide range of cutting conditions, including high-speed cutting. To obtain products that are domestically and internationally competitive, we need to optimize cutting processes, in which the tool is the weakest link in the technological chain. Defects of the cutting tool impair the productivity and product quality. In the present work, the wear of cutting tools produced by the sintering of high-speed steel powder is studied. Tool materials based on high-speed steel with additional alloying by titanium carbide (carbide steel) are shown to be highly wear-resistant. They may be classified as a new category of self-organizing tool materials. The results indicate the expediency of additional alloying by two methods to modify the tool friction and wear: (1) alloying with compounds that considerably reduce the self-organization by decreasing the frictional coefficient at working temperatures; (2) alloying to expand the range of self-organization. Both methods result in lower frictional forces and temperatures, as confirmed by the change in wear resistance and frictional characteristics. The wear resistance of such tools is found to be 2–3.5 times that of regular high-speed steel tools.