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7th CIrP Conference on Surface Integrity, CSI 2024

作者： Zhou, Jinming Frejd, Stefan Slipchenko, Kateryna Hrechuk, Andrii M'Saoubi, rachid Division of Production and Materials Engineering Lund University Lund Sweden Seco Tools AB R&D Material and Technology Development Fagersta Sweden

Challenges in drilling nickel-based superalloys, such as Inconel 718 (IN718), are multifaceted. High requirement of hole surface quality in drilling such alloy must deal with extreme material properties and complex process condition in drilling operation. This paper presents an experimental investigation on the effect of PVd coated solid carbide drills under different internal cooling schemes on hole quality in drilling IN 718 alloy. Three types of solid carbide drills were used in the series of drilling experiments, including PVd coated and uncoated drills, and different design in the number of internal cooling channels, two channels and four channels. The objective of the investigation is to assess the effect of coating and efficiency of internal cooling on surface quality in drilling IN718 alloy. Surface quality on drilled holes in terms of roughness, burr formation, subsurface deformation and strain hardening has also been measured and analyzed on the machined specimen. The roughness and burr size on drilled holes demonstrated little differences among the three types of testing drills. Surface roughness was severely deteriorated by the chip trapped in the hole leaving scratch and smears on the surface. Nevertheless, the scheme of internal cooling channels and PVd coating exhibited noticeable influence on quality of drilled hole surface. © 2024 The Authors. Published by Elsevier B.V.

关键词： Superalloys

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Effect of cooling scheme and coating of drills on hole quality in drilling of Inconel 718

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Procedia CIrP 2024年 123卷 137-142页

作者： Jinming Zhou Stefan Frejd Kateryna Slipchenko Andrii Hrechuk rachid M’Saoubi Division of Production and Materials Engineering Lund University Lund Sweden Seco Tools AB R&D Material and Technology Development Fagersta Sweden

关键词： drill Superalloy Surface quality PVd coating Cooling Burr

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Evolution of surface quality in micromilling Ti-6Al-4V alloy with increasing machined length 7

Evolution of surface quality in micromilling Ti-6Al-4V alloy...

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7th CIrP Conference on Surface Integrity, CSI 2024

作者： Gonçalves, Maria Clara Coimbra Alsters, rob Curtis, david 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 R&D Materials and Technology Development Seco Tools AB Fagersta737 82 Sweden Division of Production and Materials Engineering Lund University Ole Römers väg 1 Lund221 00 Sweden

Micromilling is a subtractive manufacturing process that presents challenges due to scale effects and rapid tool wear. To understand the evolution of surface quality when increasing the machined length during the micromilling process, this study assessed the surface roughness, topography, and defects of slots micromilled on Ti-6Al-4V. For the experiments, 1 mm diameter flat end mills were employed, and the cutting parameters were varied using a full factorial design. Subsequently, the surface texture field parameter Sa was assessed every 20 mm, up until the machining length of 260 mm. The analysed results led to the conclusion that, for the adopted set of parameters and the machining length of up to 260 mm, surface roughness was not significantly correlated to the machined length in the micromilling process of Ti-6Al-4V, as the Pearson coefficient, obtained from the correlation analysis, was -0.052. However, the surface roughness was mainly influenced by feed rate (Pearson coefficient of 0.82), with higher feed rates leading to roug surfaces (up to Sa = 0.4 μm) duhere to the tool load increase that causes wider feed marks on the surface. regarding the feed marks, they were affected by the tool rotational frequency due to system vibration. Additionally, surface defects of adhered material, smearing, tearing and side flow were observed. For lower feeds, material adhesion was the main type of defect observed, while higher feed rates favoured the side flow phenomenon. © 2024 The Authors. Published by Elsevier B.V.

关键词： Surface roughness

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

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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 570卷

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 571卷

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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Evolution of surface quality in micromilling Ti-6A1-4V alloy with increasing machined length

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Procedia CIrP 2024年 123卷 221-226页

作者： Maria Clara Coimbra Gonçalves rob Alsters david Curtis rachid M’Saoubi Hassan Ghadbeigi University of Sheffield Mechanical Engineering Department Mappin Street Sheffield UK R&D Materials and Technology Development Seco Tools AB Zandterweg 14 5973 RC Lottum Netherlands Advanced Manufacturing Research Centre University of Sheffield Rotherham S60 5TZ UK R&D Materials and Technology Development Seco Tools AB 737 82 Fagersta Sweden Division of Production and Materials Engineering Lund University Ole Römers väg 1 221 00 Lund Sweden

Micromilling is a subtractive manufacturing process that presents challenges due to scale effects and rapid tool wear. To understand the evolution of surface quality when increasing the machined length during the micromilling process, this study assessed the surface roughness, topography, and defects of slots micromilled on Ti-6A1-4V. For the experiments, 1 mm diameter flat end mills were employed, and the cutting parameters were varied using a full factorial design. Subsequently, the surface texture field parameter S a was assessed every 20 mm, up until the machining length of 260 mm. The analysed results led to the conclusion that, for the adopted set of parameters and the machining length of up to 260 mm, surface roughness was not significantly correlated to the machined length in the micromilling process of Ti-6A1-4V, as the Pearson coefficient, obtained from the correlation analysis, was -0.052. However, the surface roughness was mainly influenced by feed rate (Pearson coefficient of 0.82), with higher feed rates leading to roug surfaces (up to S a = 0.4 µm) duhere to the tool load increase that causes wider feed marks on the surface. regarding the feed marks, they were affected by the tool rotational frequency due to system vibration. Additionally, surface defects of adhered material, smearing, tearing and side flow were observed. For lower feeds, material adhesion was the main type of defect observed, while higher feed rates favoured the side flow phenomenon.

关键词： micromilling surface quality tool wear

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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 570卷

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 570卷

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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Tribological Considerations when Modelling Tool Wear in Turning of 15-5PH Stainless Steel 9th

Tribological Considerations when Modelling Tool Wear in Turn...

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9th International Conference on Tribology in Manufacturing Processes and Joining by Plastic deformation, ICTMP 2021

作者： Methon, Grégory Courbon, Cédric M’saoubi, rachid Girinon, Mathieu rech, Joël University of Lyon ENISE LTDS CNRS UMR 5513 58 Rue Jean Parot Saint-Etienne42000 France R&D Material and Technology Development Seco Tools AB FagerstaSE-73782 Sweden CETIM 52 avenue Félix-Louat Senlis60300 France

ISBN: (纸本)9783035717242

The present work proposes to emphasize the effects of friction and wear formulations for wear prediction for turning operations. It is shown that friction models play a major role on local variables such as pressure, sliding speed and temperature (σn, Vsl, T) and thus on the simulated tool wear. This work highlights that both formulations and parameters of these equations should be carefully considered to achieve an actual predictive capability. © 2022 Trans Tech Publications Ltd, Switzerland.

关键词： Friction

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