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On the wear mechanisms of uncoated and coated pcBN tools during turning of 17–4 PH martensitic stainless steel

International Journal of refractory Metals and Hard materials 2025年 127卷

作者： Bjerke, A. Casas, J. Lenrick, F. Andersson, J.M. M'Saoubi, r. Bushlya, V. Division of Production and Materials Engineering Lund University Box 118 Lund22100 Sweden R&D Materials and Technology Development Seco Tools AB Fagersta737 82 Sweden

Polycrystalline cubic boron nitride (pcBN) is a very promising tool material for turning martensitic stainless steels at high cutting speeds (vc > 200 m/min). The competitive advantage of pcBN over cemented carbide increases as the cutting speed is increased. Changing the speed might lead to a shift in the wear balance and hence the knowledge about tool wear below vc = 200 m/min might not be applicable at vc = 600 m/min. The coatings designed for the lower speed range might also not be performing in the same way at higher speeds. This paper investigates the wear mechanism of uncoated and (Ti,Al)N coated pcBN tools when turning 17–4 PH in a hardened condition at speeds vc = 200–600 m/min. Both scanning and transmission electron microscopy are used to study the worn tools. The in-depth analysis reveals that adhesive wear is only active at low speeds. Increasing the speed does however lead to more wear by diffusion and oxidation. The cBN is preferentially worn out, leaving the TiC binder at the tool-chip interface. Oxidation results in the accelerated wear of the pcBN but also in the formation of metal oxides within the adhered build up layer. The (Ti,Al)N coating does not significantly extend the tool life within this speed range, but it suppresses the adhesive wear mechanism preventing premature tool failure. © 2024 The Author(s)

关键词： Cubic boron nitride

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Efficient predictive simulation of tool wear in face milling using an advanced 3d numerical approach

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Wear 2025年

作者： Methon, Grégory Courbon, Cédric Auzenat, François M'Saoubi, rachid Girinon, Mathieu rech, Joël Ecole Centrale de Lyon CNRS ENTPE LTDS UMR5513 ENISE 42023 Saint Etienne France R&D Milling and Process Seco Tools AB 22 avenue de la prospective 18020 Bourges France R&D Material and Technology Development Seco Tools AB FagerstaSE-73782 Sweden Cetim 7 rue de la Presse Saint-Etienne42952 France

Being able to predict tool life and the optimal cutting conditions for any combination of cutting tool system and workmaterial is clearly an up-to-date research issue. This work presents an innovative strategy for predicting efficiently tool wear in face milling operations. The primary objective is to develop a methodology capable of handling complex 3d geometries and tool paths within an industrially acceptable computing time. The approach involves a new 3d multi-scale numerical method based on discretizing the tool cutting edge into 2d elementary sections. A 2d Arbitrary Lagrangian-Eulerian (ALE) finite element cutting model is employed to compute local contact pressure, sliding velocity, and heat flux along each section in parallel. An elementary wear equation is applied to calculate the local wear rate after a given time increment, simulating all 2d worn profiles. These profiles are then merged to generate the updated 3d geometry of the worn tool. An iterative procedure is conducted to simulate the evolution of the cutting tool geometry over an extended cutting period. By achieving a good agreement with experimental results in a reasonable computation time, this strategy demonstrates significant potential for optimizing tool life and performance in milling operations. © 2025 Elsevier B.V.

关键词： Milling (machining)

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Performance and wear mechanisms of TiAlN-NbN coated cemented carbide in milling Ti6Al4V with different cooling and lubrication approaches

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Wear 2025年

作者： Lindvall, rebecka Casas Gayubo, Josu Gutnichenko, Oleksandr Auzenat, François M'Saoubi, rachid Bushlya, Volodymyr Division of Production and Materials Engineering Lund University Ole Römers Väg 1 Lund221 00 Sweden R&D Milling and Process Seco Tools France 22 Avenue de La Prospective Bourges18 000 France R&D Materials and Technology Development Seco Tools AB Fagersta737 82 Sweden

Titanium alloys are difficult-to-machine materials given their high strength, the high temperatures generated, and the naturally short contact length that combined result in rapid tool wear. different machining strategies can be employed to cope with the low machinability. This study investigates the machining performance using different cooling and lubrication methods during down face milling of the most employed Ti alloy Ti6Al4V. The conditions include a dry environment, flood coolant, and sustainable vegetable oil applied at minimum quantity lubrication (MQL) condition. The tool life at dry conditions and with MQL applied vegetable oil are similar but MQL shows promising potential in prolonging tool life. Flood coolant provided no beneficial effect and tool life was about 50 % shorter as to dry and MQL conditions. The tool wear evolution on as-worn tools and their cross-sections is studied in scanning electron microscope using X-ray energy-dispersive spectroscopy. The PVd applied TiAlN-NbN coated WC-12%Co tools are worn by mechanical fracturing which is additionally accelerated by the outward diffusion of C from WC and Co binder that facilitate WC grain pull-out. Oxidation of Co binder further weakens the tool material mechanically. © 2025 The Authors

关键词： Titanium alloys

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Analysis of tool wear in micromilling Ti6Al4V and its impact on generated surface integrity

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Wear 2025年

作者： Gonçalves, Maria Clara Coimbra Alsters, rob Curtis, david Bushlya, Volodymyr M'Saoubi, rachid Ghadbeigi, Hassan University of Sheffield Mechanical Engineering Department Mappin Street Sheffield United Kingdom R&D Materials and Technology Development Seco Tools AB Zandterweg 14 Lottum5973 RC Netherlands Advanced Manufacturing Research Centre University of Sheffield RotherhamS60 5TZ United Kingdom Lund University Ole Römers väg 1 Lund221 00 Sweden R&D Materials and Technology Development Seco Tools AB Fagersta737 82 Sweden

Tool wear is one of the dominant factors that impacts the surface integrity of machined materials. Understanding the impact of tool wear on surface integrity is crucial in micromilling, due to the size of the features being machined and the cutting tools. Therefore, this work aims to analyse the impact of tool wear on surface integrity during the micromilling of Ti6Al4V. In this context, microslots were manufactured on a Ti6Al4V workpiece using both coated and uncoated 1 mm flat end mills at constant cutting parameters with varying cutting lengths in order to analyse the progression of tool wear with machined length and its impact on surface integrity. The microtools were investigated using both Scanning Electron Microscope (SEM) and infinite focus optical imaging (Alicona) to determine the tool wear evolution. Surface integrity was assessed by analysing surface roughness areal parameters, surface microscope images, and subsurface microstructure and microhardness perpendicular to the cutting direction. The results show that surface quality was not affected by the evolution of tool wear, with surface topography, including surface roughness parameters, remaining within a similar range until the catastrophic failure of the tool. Analysis of the machined surface revealed small chips adhered to it, which affected the surface texture height measurements, leading to a predominance of atypical peaks on the surface. Subsurface analysis of the machined material showed that the microstructure and microhardness remained consistent with the bulk material characteristics, indicating no evidence of severe plastic deformation in the machined subsurface. However, once the tool failed and began rubbing against the workpiece surface, swept grains due to material dragging and heat-affected zones were observed in the subsurface microstructure. Swept grains, caused by material extrusion, were also observed in the microstructure of the top burr formation regions throughout the experiments

关键词： Titanium alloys

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Influence of the design of Ti (C, N)-based cermets with alternative binders on their performance and wear in milling

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Wear 2025年

作者： Premkumar, Vikas B.K. Chalkiadakis, Evangelos M'Saoubi, rachid Bushlya, Volodymyr Production and Materials Engineering Lund University Ole Römers Väg 1F Box 118 Lund221 00 Sweden R&D Materials and Technology Development Seco Tools AB FagerstaSE-73782 Sweden

Ti (C, N) based cermet materials are predominantly used in continuous finishing applications of metal cutting due to their high hardness, excellent resistance to oxidation and high chemical stability. However, their application in interrupted cutting like milling are limited due to their brittle-like failure due to low fracture toughness. In this work, alternative binder systems such as Co-Ni and Ni are investigated to study their influence on the material properties followed by evaluating their performance in face milling of quench and tempered 42CrMo4 steels having a hardness of 35 HrC. The results show that as the concentration of Ni in the binder increases, the hardness (HV) decreases and the Palmqvist fracture toughness (K1C) increases. This trend is more pronounced in the binder containing pure Ni. Thus, Ni helps in transforming the nature of a brittle-like cermet with Co binder to a tougher cermet with Co-Ni and pure Ni binder. Up-milling tests with coolant revealed that as-sintered cermet with pure Co and Co-Ni binder performed similarly while pure Ni binder showed premature failure. CVd coated cermet in as-deposited state shows a substantial improvement in performance of the Co-Ni binder compared to pure Co binder while Ni binder show rapid flaking of coating causing premature failure. Formation of comb cracks and parallel cracks networks followed by adhesion and impaction of steel in the cracks is observed as the main wear mechanism that causes rapid block isolation of the geometry leading to tool catastrophic failure. However, CVd coated Co-Ni binder system showed less adhesion in the crack networks which is speculated to be the reason for its improved performance. © 2025 The Authors

关键词： Cracks

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A physics-based flow stress model for cutting simulation of additively manufactured Alloy 718

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CIrP Annals 2025年

作者： Malakizadi, Amir M'Saoubi, rachid Department of Industrial and Materials Science Chalmers University of Technology Gothenburg Sweden R&D Materials and Technology Seco Tools AB Fagersta Sweden Division of Production and Materials Engineering Lund University Lund Sweden

A dislocation-based flow stress model is proposed to describe the behavior of Alloy 718 fabricated using laser-based and electron-beam powder bed fusion methods. This physics-based model is adaptive to microstructural variations including the size and volume fraction of γ″ precipitates, crystallographic texture, grain size and the density of immobile dislocations. Coupled with data from thermodynamic and kinetic simulations, as well as insights from advanced characterization methods, this model provides a framework for assessing machinability of additively manufactured Alloy 718. The predicted cutting forces and chip shape parameters showed a good agreement with the corresponding measurements. © 2025 The Author(s)

关键词： dislocations (crystals)

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Optimal modelling of Colding parameters for round inserts with respect to tool use-time criteria 20

Optimal modelling of Colding parameters for round inserts wi...

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20th CIrP Conference on Modeling of Machining Operations in Mons, CIrP CMMO 2025

作者： Bello Bermejo, Juan Manuel Saatçi, Berk Johansson, daniel Hägglund, Sören Ståhl, Jan-Eric Windmark, Christina Division of Production and Materials Engineering Lund University LTH Ole Römers Väg 1 Lund221 00 Sweden R&D Seco Tools AB Björnbacksvägen 10 Fagersta737 47 Sweden Production Technology University West Gustava Melins Gata 2 Trollhättan461 86 Sweden

Optimization of machining processes, such as milling, is essential for industrial efficiency and product quality. To achieve greater efficiency, it is necessary to understand how tools wear down in different conditions in order to anticipate possible undesirable events like sudden breakage or unpredictable degradation. This study focuses on understanding tool wear in dry milling of compacted graphite iron (CGI) EN-GJV-450 using PVd-coated cemented carbide and cBN tools to predict tool life effectively. The research builds on the Colding model, an empirical framework for tool life estimation, by incorporating and comparing two chip thickness concepts in order to optimize the Colding model's performance, maximum chip thickness (hmax) and equivalent chip thickness (he). Through systematic experimentation and modelling, this work has identified optimal conditions for tool life prediction, with hmax offering a potentially resource-efficient cross-validation alternative aligned with sustainability goals. The results demonstrate that the optimized Colding model effectively predicts tool life for both coated cemented carbide and cBN cutting tools with round geometry in dry milling of CGI. The insights gained further enhance our understanding of the milling process and provide a solid foundation for selecting appropriate machining parameters to extend tool life and improve process efficiency. © 2025 The Author(s).

关键词： Milling (machining)

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Investigation on cutting fluid use in finish milling of polylactide (PLA) 3d-printed parts 20

Investigation on cutting fluid use in finish milling of poly...

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20th CIrP Conference on Modeling of Machining Operations in Mons, CIrP CMMO 2025

作者： Lorenzoni, Margaux Spitaels, Laurent rivière-Lorphèvre, Edouard Odent, Jérémy M'Saoubi, rachid Cloëz, Liam Fontaine, Michaël ducobu, François Machine Design and Production Engineering Lab Research Institute for Materials Science and Engineering University of Mons Place du Parc 20 Mons7000 Belgium University of Mons Place du Parc 20 Mons7000 Belgium R&D Material and Technology Development Seco Tools AB Björnbacksvägen 2 FagerstaSE-737 82 Sweden Department of Mechanical Engineering Sciences Division of Production and Materials Engineering Lund University Ole Römers väg 1 LundSE-221 00 Sweden FEMTO-ST Institute-Applied Mechanics Dept. Université de Franche-Comté-SUPMICROTECH-CNRS Rue de l'épitaphe 24 BesançonF-25000 France

Fused Filament Fabrication (FFF) is an additive manufacturing process based on material Extrusion (MEX) of polymeric filament. This manufacturing technology is commonly used for personalized production applications and prototyping, allowing to obtain customized parts with complex geometries at a low cost. However, this production technique has its limitations regarding dimensional accuracy and surface roughness of the final parts. To overcome these limitations, finish milling is considered to be a promising technique as it is widely used for metallic parts. Yet, the specific thermal properties of polymers such as low thermal conductivity and low melting temperature are adding a challenge in the determination of optimal cutting conditions. In this context, the use of cutting fluid could be the key to keep the material from melting during milling. Therefore, this paper proposes to compare the impact of using a compressed air flow to dry conditions on the cutting forces and the surface quality obtained on 3d-printed polylactide (PLA) parts. The qualification test of the tool-material couple standard (NF E 66-520-6) will be used as a guideline to determine the relevance of cutting fluid use for cutting conditions varying around an operating point. Moreover, simulated cutting forces using a mechanistic model will be compared to experimental data to evaluate the applicability of the model. © 2025 The Authors.

关键词： Compressed air

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Optimal modelling of Colding parameters for round inserts with respect to tool use-time criteria

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Procedia CIrP 2025年 133卷 286-291页

作者： Juan Manuel Bello Bermejo Berk Saatçi daniel Johansson Sören Hägglund Jan-Eric Ståhl Christina Windmark Division of Production and Materials Engineering Lund University LTH Ole Römers Väg 1 Lund 221 00 Sweden R&D Seco Tools AB Björnbacksvägen 10 737 47 Fagersta Sweden Production Technology University West Gustava Melins Gata 2 Trollhättan 461 86 Sweden

Optimization of machining processes, such as milling, is essential for industrial efficiency and product quality. To achieve greater efficiency, it is necessary to understand how tools wear down in different conditions in order to anticipate possible undesirable events like sudden breakage or unpredictable degradation. This study focuses on understanding tool wear in dry milling of compacted graphite iron (CGI) EN-GJV-450 using PVd-coated cemented carbide and cBN tools to predict tool life effectively. The research builds on the Colding model, an empirical framework for tool life estimation, by incorporating and comparing two chip thickness concepts in order to optimize the Colding model’s performance, maximum chip thickness (h max ) and equivalent chip thickness (h e ). Through systematic experimentation and modelling, this work has identified optimal conditions for tool life prediction, with h max offering a potentially resource-efficient cross-validation alternative aligned with sustainability goals. The results demonstrate that the optimized Colding model effectively predicts tool life for both coated cemented carbide and cBN cutting tools with round geometry in dry milling of CGI. The insights gained further enhance our understanding of the milling process and provide a solid foundation for selecting appropriate machining parameters to extend tool life and improve process efficiency.

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Investigation on cutting fluid use in finish milling of polylactide (PLA) 3d-printed parts

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Procedia CIrP 2025年 133卷 656-661页

作者： Margaux Lorenzoni Laurent Spitaels Edouard rivière-Lorphèvre Jérémy Odent rachid M’Saoubi Liam Cloëz Michaël Fontaine François ducobu Machine Design and Production Engineering Lab – Research Institute for Materials Science and Engineering University of Mons Place du Parc 20 7000 Mons Belgium Laboratory of Polymeric and Composite Materials (LMPC) – Center of Innovation and Research in Materials and Polymers (CIRMAP) University of Mons Place du Parc 20 7000 Mons Belgium R&D Material and Technology Development Seco Tools AB Björnbacksvägen 2 SE-737 82 Fagersta Sweden Department of Mechanical Engineering Sciences - Division of Production and Materials Engineering Lund University Ole Römers väg 1 SE-221 00 Lund Sweden FEMTO-ST Institute – Applied Mechanics Dept. Université de Franche-Comté – SUPMICROTECH – CNRS Rue de l’épitaphe 24 F-25000 Besançon France

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