Cutting Tool Materials for High Speed Machining＊

PROGRESS IN NATURAL SCIENCE Vol .15 , N o .9 , September 2005

Cutting tool materials for high speed machining＊

LIU Zhanqiang ＊＊ and AI Xing (School of Mechanical Engineering , S handong University , Jinan 250061 , China)

Received Feb ruary 22 , 2005 ;revised March 28 , 2005

Abstract High speed machining (HSM)is one of the emerging cutting processes, w hich is machining at a speed significantly higher than the speed commonly in use on the shop floor .In the last tw enty years, high speed machining has received g reat attentions as a technological solution for high productivity in manufactu ring .This article review s the developments of tool materials in high speed machining operations, and the properties, applications and prospective developments of tool materials in HSM are also presented .

Keywords: tool materials, high speed machining.

High speed machining processes can produce plications fo r each type of the material . more accurate parts , as well as reduce the costs asso- ciated w ith assembly and fixture storage by allow ing several procedures to be combined into a mo nolithic one[ 1] .There has been a stro ng resurgence of interest in high speed machining technology , so that it has become one of the most promising advanced manufacturing technologies in the last tw enty years .Hig h speed machining technology has already been applied to many manufacturing industries such as the aviation and aerospace industry , automobile industry , mould industry to cut steel , cast iron and its alloys , aluminum and magnesium alloys , super alloy s of nickel- based , cobalt-based , ferrous-based , titanium-based , Fig .1 . Variety of tool materials in high speed machining. etc .and composite materials[ 2] .The applications of 1 .1 Diamond high speed machining are continuing to rapidly ex- pand . Diamond has the highest hardness, heat co nduc- In o rder to explore the w ide applications of hig h tivity among the substances and is excellent in chemi- speed machining , recent developments and applica- cal stability .The four types of diamonds being used tions of the tool materials in hig h speed m achining are as cutting tools are industrial grade natural diamond presented in this paper . (ND), synthetic single crystal diamond , poly crystalline diamond (PCD), and chemical vapor deposition 1 Recent developments of tool materials in (CVD) diamond coating (including thin-film and [ 4] high speed machining thick-film diamond coating s) .

M any ty pes of tool materials , ranging from dia- Natural diamond is the most expensive tool ma- monds to ceramics and to high speed steel (HSS), are terial .Because the ex tremely sharp edge of a blade is used as cutting tools in today' s machining industry[ 3] obtained , natural diamond is m ainly used in some ul- (see Fig .1).It is important to be aware that differ- tra-precision m achinings , such as the machining of ences in properties do exist among tool materials (see micro-mechanical parts , retro reflectors , navigating Table 1), these differences determine the correct ap- gy roscopes, and hard disc chips , etc .

＊ S upported by National Natural S cience Foundation of China (Grant No .50375089), Fok Ying Tung Education Foundation (Grant No.91054), the Natural S cience Foundation of Shandong Province, China (Gran t No .Y2003F06), and the Program for New Century Excellent Talents in Univer- sity ＊＊ To w hom correspondence should be addressed .E-mail:melius@sdu .edu .cn 778 w ww .tandf.co .uk/journals Prog ress in Natural Science Vol .15 No .9 2005

Table 1 . Main properties of some tool materials Properties Diamond CBN Cemented carbide Cerm et Silicone nitride Alumina Density(106 kg/ m3) 3 .5 3 .5 14 .5 6 .8 3 .2 4 .2 Hardness(Hv) 10000 5000 1500 1600 1600 2500 Strength (kg/ mm2) — 110 250 200 120 40 Young modulus(104 kg/ mm2) 10 .5 7 .3 60 40 3 .1 3 .6 Thermal conductivity (W/mK) 2000 (single crystal) 50 76 13 40 20

Synthetic single crystal diamond has good di- mension, shape and function stability .It is mainly used in machining of wood , for exam ple , w ood floor- board coated with Al2O 3 .

PCD is obtained with some binders such as cobalt pow ders by sintering under ultra-high pressure and high temperature under w hich condition the diamond is chemically safe .This sintered diamond body shows excellent abrasion resistance w ith the cutting of the nonferrous metals as well as nonmetallic material and is taking an active part as the high accuracy , hig h ef- Fig .2 . S tructures of diamond and CBN . ficiency cutting tool for the difficult processing sub- materials with hardness greater than H RC 45 such as stances such as the Al-Si alloy and cemented carbide . automobile parts , the engine blocks and gears, CVD diamond coating tools are w ell suited fo r shafts , bearing s.Generally speaking , PCBN machin- the high speed machining of aluminum and other non- ing operations should be run dry .It can be run at cut- ferrous alloys such as copper , brass , bronze , and ting speeds above 2000 m/min in machining of gray abrasive advanced composites such as g raphite , car- cast iron materials .The largest recent g row th in the bon-carbon , g lass-fiber reinfo rced plastics , and car- use of PCBN inserts is in the area of high speed hard bon-filled phenolics[ 5 —9] .CVD thin-film diamond can machining —in particular , the finish machining of be applied to such complex tool geometries as inserts steel-alloy automotive engine compo nents , such as w ith chip breakers , solid end mills , routers , and gears , shafts and bearings , w hich have hardness be- drills.Thick-film diamond coating tools currently tw een HRC 60 and H RC 65 .These parts have tradi- find their use in high speed machining of high-eutec- tionally been ground to very tight dimensional toler- tic aluminum alloys[ 10, 11] . ances and a fine surface finish .

1 .2 CBN The mechanical and therm al properties of CBN are influenced largely by the kinds and addition quan- Cubic boron nitride (CBN)is synthesized artifi- tities of the binders that are used in the case .The cially under the condition of the high pressure and bond phases of PCBN are Co , Ni or TiC , TiN , high tem perature as the same as the diamond .It is al- Al2O3 , etc .The CBN grain size and bond phase af- so similar to diamo nd in its polycry stalline structure fect the PCBN machining perform ances .PCBN w ith (see Fig .2). low co ntent CBN (50 %—65 %)is mainly used in finishing hardened steel (HRC45-65), while high CBN has sm all reactivity w ith the iron system content CBN (80 %—90 %)is used in high speed materials and is mo re chemically and thermally stable rough , semi-finishing of nickel and chromium cast than those of the diamond .Because of these proper- iron , intermittent machining of hardened steel, hard ties , the CBN has been paid attention as the tool m a- metal, sintered metal, and heavy alloy , etc . terial that is useful fo r machining of iron sy stem m a- terials for w hich the diamond is unable . The binder-less sintered CBN w hich does not include any binder is developed recently[ 12—14] .The Polycry stalline ty pe CBN (PCBN)has an ex cel- binder-less CBN is synthesized by controlling the con- lent characteristic for cutting tools to machine the cast dition of the CBN particle to be fine particles having iron and heat resisting alloy , and the iron system hard high therm al conductivity , excellent thermal stabili- Prog ress in Natural Science Vol.15 No .9 2005 w ww .tandf.co .uk/journals 779 ty , high hardness and streng th even under hig h tem- of composites and super alloy materials used in the perature .The binder-less CBN cutting tool is now aerospace industry , such as nickel-based alloy s , but considered as the cutting tool m aterial of the nex t are not suitable for machining of cast irons and steels. generation . 1 .4 TiC(N)-based cemented carbides 1 .3 Ceramic cutting tool TiC (N )-based cemented carbides are mostly Ceramics are non-metallic materials.Some ad- compose of titanium carbon nitride (TiCN )w ith a vantages of ceramic tools are ex tremely high resis- nickel or cobalt bonder[ 21] .They are hard and chemi- tance to abrasive w ear , cratering , and extremely hig h cally stable , which leads to hig her w ear resistance . temperature hardness[ 15] .There are tw o major classes Cermets w ork in materials such as steels and ductile [ 22] of ceramic tool materials available :alumina (A12O3)- irons that produce a ductile chip .Their increased based ceramics and silicon nitride (Si3N 4)-based ce- speed capability enables them to machine carbon ramics . steels, stainless steels, ductile irons , and cast irons at high cutting speeds and to produce better surface finishes . Alumina-based ceramics has g ood chemical sta- The most common cermets are :(1)TiC-based bility and low affinity w ith ferrous metals .It is there- [ 23] fore not susceptible to adhesion .The solubility of alu- carbide such as TiC +Ni o r M o w ith high wear re- mina in iron is only one fifth of that of tungsten car- sistance , and TiC +TaC +WC +Co w ith hig h frac- bide (WC).Hence , alumina-based ceramics is with ture toughness , (2)TiN-based carbide w ith enhanced low diffusio n wear and very high anti-oxidization . fracture toughness , and (3) TiCN-based carbide How ever , alumina-based ceramics has low er (TiCN +NbC)with higher w ear resistance and ther- strength , fracture toughness , thermal conductivity , mal shock resistance .Cermets are very suitable for and thermal shock resistance .It has better perfor- high speed finish machining of steel alloys and cast irons . mance than Si3N 4-based ceramic tools in high speed machining of steels. 1 .5 Coated tools

In comparison w ith alumina-based ceramics , Performance at higher temperatures is a goal of Si3N 4-based ceramics has higher strength , fracture many tool material developers .The answ er seems to toughness, and thermal shock resistance .It has a lie in coatings added to the tool tip to improve cutting lower thermal expansion coefficient , Young' s modu- capabilities .Coating s include a blend of materials that lus , and chemical stability than Al2O 3-based ceram- resists heat and fracture , maintains a cutting edge , ics .The Si3N4-based ceramics is not susceptible to and strengthens the bond between coating compo- adhesion with iron .Therefore , it is mainly used in nents and the base materials[ 24] . the high speed machining of cast iron . Tw o widely used coating methods are chemical Si3N 4-Al2O3(sialon)ceramic tools have relatively vapor deposition (CVD)and phy sical vapor deposition [ 25 —27] high streng th , fracture toughness , anti-oxidization , (PVD) .CVD coating s first appeared in the [ 28] thermal conductivity , thermal shock resistance and 1970s .This process is carried out in a vacuum creep resistance at high tem peratures[ 16] .While it has chamber in w hich the coating material is applied to a low heat expansion coefficient , sialo n ceramic tools tool by vacuum sputtering or arc-evapo ration .Initial- are generally not suitable for the machining of steels , ly the coating w as carbide , then titanium nitride , fol- it is m ainly used in the rough machining of cast iron low ed by titanium carbon nitride and aluminum ox- and nickel-based alloy[ 17 , 18] . ide .Today CVD-coated , cobalt-enriched inserts will be used in 40 %—50 % of general machining opera- In o rder to further improve the performance and tions .The PVD coating process is similar to CVD but w ear resistance of ceramic tools to machine new w ork can be carried out at around 500 ℃ (as opposed to materials and composites , w hisker-reinforced[ 19] m a- 1000 ℃), and does not adversely affect steel .PVD terials including silicon nitride-based and alumina- w as initially developed fo r HSS and later applied to based tools, reinfo rced w ith silicon carbide (SiC) carbide[ 29] .With the CVD process , most coatings are w hiskers have been developed[ 20] .Such reinforced ce- multilayers.With PVD , both mono and multilayer ramic tools are very effective in high speed machining coating[ 30 —34] processes are feasible . 780 w ww .tandf.co .uk/journals Prog ress in Natural Science Vol .15 No .9 2005

The three coating s most widely used today are ti- ing m aterials by applying such ceramic coating to the tanium nitride (TiN), w hich w as introduced in the tools[ 44, 45] . 1980s, titanium carbonitride (TiCN)[ 35—38] , and titanium aluminum nitride (TiAlN )[ 39—43] .TiN is New hard coating s have recently been developed considered a good general-purpose coating and is easi- such as PVD of carbon nitride (CNx), nitride (TiN/ NbN , CrN[ 31] , TiN/VN), DLC (diamond like car- ly recognized by its gold color .The advantages of [ 46—48] [ 49] TiN coating are increased surface hardness , increased bon coatings) , CBN coating etc .These tool life , better w ear resistance , and hig her lubricity , coatings have good thermal stability under elevated w hich provides less friction and reduces edge build- temperature and w ill be w idely used in hig h speed up .TiN coating is mostly recom mended for m achin- machining . ing low alloy steel and stainless steel.TiCN coating is PVD/CVD coatings are also combined in the g ray colored , and even harder compared to TiN .Its same coating/substrate system .An underlying CVD advantages are increased cutting speed and feeds layer can provide exceptional adherence to the sub- (40 % to 60 % higher com pared to TiN ), g reater strate , while the smoo th PVD outer layer permits metal removal rates , and superior wear resistance . higher cutting speeds and lower cutting forces . TiCN coating s are recom mended for m achining all material types .TiAlN coating appears gray or black Nano-coatings are made of hundreds of layers and is primarily used to coat carbide .It can w ork at that are only a few nanometers thick[ 50, 51] .Nano- very high tem peratures (800 ℃), w hich makes it sized-coating composites promise high tem perature ideal for high speed machining w ithout coolant .Pres- hardness , streng th and fracture toughness since they surized air is recommended to remove chips from the have a g reater number of grain boundaries , w hich is cutting zone .It wo rks w ell on hardened steels, tita- directly related to the decreased size of each grain . nium and nickel alloys , as well as abrasive materials The hardness for nano-coatings measures about 2800 like cast iron . to 3000 on the Vickers scale and exhibits a 5 to 50 percent increase in wear resistance compared to mate- Because ceramics has many ex cellent properties rial made of submicron pow ders .It has been reported such as the wear resistance , therm al resistance , cor- that grades with 62 alternating layers of titanium car- rosion resistance , it becomes possible to make the u- bide (TiC)and titanium carbon nitride have been de- nique composite material that combines the ex cellent veloped . advantage of the base material and ceramics by coating of the ceramics .It improves tool life more sub- The most commonly used coatings for machining stantially by the reduction of w ear resistance , friction of steels and cast irons available on the market are coefficient in comparison with the conventional coat- specified in Tables 2 and 3 , respectively .

Table 2 . S pecification of the selected coatings for steel Coating structure Recommended applications Notes I .Universal g rades PVD-TiN on a very tough micrograin Used for all P , M , and K groups of m aterials Especially for high quality th reading CVD-TiC/ TiCN/ TiN With a w ide field application for steels Low and medium cutting speeds

CVD-TiCN/ TiN-TiC-TiCN/ Al2O 3/ TiN First choice for steels and most types of ma- Combines good w ear resistance w ith high chining operations toughness

CVD-TiCN/ Al2O 3/ TiN with thick ceramic With a w ide field application for steels Can be used for cast iron layer and cobalt-enriched substrate

CVD-TiC +TiCN/α-Al2O 3 with thick ceramic For finishing and medium roughing of carbon The most w ear-resistant of universal grades layer and alloy steels

CVD-Al2O 3-Ti(N , B) w ith multiple ceramic High-speed turning of carbon steels and stain- Improved oxidation and adhesion resistance layer less alloys II .C oating for specific machining application

CVD-TiCN/ TiC/ Al2O 3 For stainless steels Minimizes tendency to built-up edge

CVD-TiCN / Al2O3/ TiN on tough substrate For steels and stainless steels in interrupted cuts Excellent w ear resistance and improved tough- with a cobalt-enriched zone ness To be continued Prog ress in Natural Science Vol.15 No .9 2005 w ww .tandf.co .uk/journals 781

Continued Coating structure Recommended applications Notes

CVD-TiCN / Al2O 3/ TiN on hard substrate Dry cutting at cu tting speeds higher than Highest thermal resistance with a cobalt-enriched zone 300 m/min

CVD-TiN / Al2O 3/ TiCN/ TiC/ TiCN/ TiN on For heavily interrupted cuts Highest toughness cobalt-enriched carbide PVD-TiAlN on micrograin substrate For finish milling mold and die steels at speeds On solid square end mills and ball-nose end of 120 —150 m/ min mills PVD-TiAlN/ TiN on cermet substrate For finishing and medium operations in w et and Thermal shock and fracture resistance interrupted cutting PVD-TiN on brazed CBN tips For high precision turning of hardened steels at Smooth coating enhances edge strength and high speeds w ear resistance PVD-TiAlN on b razed CBN tips For high-speed continuous to medium inter- Excellent w ear resistance and extended tool life rupted tu rning of hardened steels

Table 3 . S pecification of the selected coatings for cast irons Coating structure Recommended applications Notes

CVD-TiCN/Al2O3/ TiN w ith thick TiCN For turning spheroidal and gray cast irons.The same High w ear and thermal resistance

and Al2O3 layers coating on tough substrate is for heavy operations

CVD-TiCN/ 2(Al2O3/ TiN For tu rning cast iron at high speeds Includes thick α-Al2O3 and thin κ-Al2O 3 layers

CVD-TiCN/Al2O3 on hard substrate For tu rning and grooving gray cast iron at high speeds Excellent flank w ear resistance

CVD-TiN/ Al2O 3/ TiN on special sub- For ductile cast irons at cutting speeds up to 200 m/ Improved adhesion resistance , ultrafine Al2O3 strate layer min layer Solid CBN coated w ith TiN High-speed machining of pearlitic gray cast iron .First Optimum w ear resistance choice for chilled cast iron

Si3N 4 ceramic coated w ith TiN and Universal grade for cast iron in continuous cuts at high Can be used w ith or w ithout coolant

Al2O 3 speeds

In contrast with the above hard coating s, coat- body tools (drills , reamers , and end mills).Ma- ing s on high speed steel such as sulfides (MoS2 , chines cutting at low speeds can mo re economically [ 52 —55] WS2)are referred to as soft coating s .They are use HSS .Over the last 20 years, HSS has been m ade mainly used in the high speed machining of hig h from pow der metal (P/M), w hich allow s manufac- strength aluminum alloy , titanium alloy and some turers to use alloys and develop microstructures that precious metals . cannot be produced by conventional fo rging metallur- gy[ 57] .These materials are m uch harder than co nven- 1 .6 Ultra fine g rain carbide tional HSS , allow ing faster cutting and providing the ability to cut harder m aterials . WC carbides with 0 .2 —1μm g rains , added with TaC , NbC , etc .having higher hardness (H RA 90 — 2 Prospective of cutting tool materials in 93 ) and streng th (2000 —3500 M Pa , up to high speed machining 5000 M Pa), can easily be fabricated to solid tools and inserts and be applied to high speed machining of fer- With respect to the main cutting tool m aterials rous-based , nickel-based , and cobalt-based hig h tem- (carbides and their related coating s, cermets , ceram- perature alloys , titanium-based alloy s, thermal resis- ics , PCBN , and diamonds)in hig h speed machining , tant stainless steels, w elded materials , and super hard the following trends are predictable :(1)Carbides: materials[ 56] . development of carbides has been m ature .Prog ress 1 .7 Power metal high speed steel w ill continue in binder enrichment techniques w hich result in increased cutting edge security and wider Originally cutting tools were simply made from range of application .(2)Hard coatings :prog ressing the hardest steel alloy anyone could find .Eventually from CVD (approximately 50 % of the coatings in use certain alloy steels became know n as high-speed steel today)to PVD (most rapidly growing coating)offers (HSS).These steels are still w idely used for round the ability to coat a sharp edge .New coating materi- 782 w ww .tandf.co .uk/journals Prog ress in Natural Science Vol .15 No .9 2005

6 Sein H ., Ahmed W .and Jackson M .Performance and characteri- als include TiAlN and TiB2 by PVD techniques , and zation of CVD diamond coated , sintered diamond and W C-Co cut- application of soft lubricious coatings such as M oS2 ting tools for dental and micromachining applications.Thin Solid and WC/C over PVD TiN or TiAlN mostly fo r Films, 2004 , 447 —448 :455 —461 . drilling and dry drilling applications will be devel- 7 Tsubota T ., Ida S ., Okada N.et al.CVD diamond coating on oped .(3)Development continues on advanced coat- WC-Co cutting tool using ECR MPCVD apparatus via elec- trophoretic seeding pretreatment .Surface and Coatings Technolo- ing s such as CBN , w hich will offer the same increases gy , 2003 , 169 —170 :262 —265 . in productivity in ferrous machining as already com- 8 Uhlmann E ., Lachmund U .and Brǜ cher M .Wear behavior of mercially available diamond coating s in non-ferrous HFCVD-diamond coated carbide and ceramic tools.Surface and applications .(4)Cermets:newer developments com- Coatings Technology , 2000 , 131(1 —3):395 —399 . bine excellent resistance to deformation and chemical 9 Ahmed W ., Rego C .A ., C herry R.et al.CVD diamond :controlling structure and morphology . 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