Comparative study of tool wear in milling titanium alloy (Ti-6Al-4V) using PVD and CVD coated cutting tool

• Published in: Industrial lubrication and tribology 2017-05, Vol.69 (3), p.363-370
• Main Authors: Raja Abdullah, Raja Izamshah, Redzuwan, Bahrin Ikram, Abdul Aziz, Mohd Sanusi, Kasim, Mohd Shahir
• Format: Article
• Language: English
• Subjects: Aerospace engineering; Aluminum; Aluminum oxide; Carbide cutting tools; Chemical vapor deposition; Coating; Comparative studies; Cutting parameters; Cutting speed; Cutting tools; Cutting wear; Design of experiments; Feed rate; High speed machining; Inserts; Machine tools; Manufacturing; Mechanical properties; Milling (machining); Noise; Optical microscopes; Organic chemistry; Physical vapor deposition; Production costs; Protective coatings; Response surface methodology; Titanium alloys; Titanium base alloys; Titanium carbonitride; Tool life; Tool wear; Tungsten carbide
• ISSN: 0036-8792; 1758-5775
• DOI: 10.1108/ILT-09-2016-0202

Purpose The purpose of this study was to compare machining performance between chemical vapor deposition (CVD)- and physical vapor deposition (PVD)-coated cutting tools to obtain the optimal cutting parameters based on different types of tools for machining titanium alloy (Ti-6Al-4V). Design/methodology/approach The design of the experiment was constructed using the response surface methodology (RSM) with the Box–Behnken method. Two types of round-shaped tungsten carbide inserts were used in this experiment, namely, PVD TiAlN/AlCrN insert tool and CVD TiCN/Al2O3 insert tool. The titanium alloy (Ti-6Al-4V) material was used throughout this experiment. The tool wear and microstructure analysis were measured using a tool maker microscope, an optical microscope and a scanning electron machine. Findings The PVD TiAlN/AlCrN insert tool produces the lowest tool wear that significantly prolongs the cutting tool life compared to the CVD TiCN/Al2O3 insert tool. In addition, depth of cut was the main factor affecting the tool life, followed by cutting speed and feed rate. Originality/value This study was conducted to compare machining performance between CVD- and PVD-coated cutting tools to obtain the optimal cutting parameters based on different types of tools for machining titanium alloy (Ti-6Al-4V). In addition, the information presented in this paper helps reduce the manufacturing cost and setup time for machining titanium alloy. Finally, tool wear comparison between PVD- and CVD-coated titanium alloys was also presented for future improvement for tool manufacturing application.