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Applying the appropriate hone design stabilizes the cutting edge, leads to improved wear behavior and higher tool life.
Experimental observations indicate higher tool life with nanocrystalline AlTiCrN coated carbide tools which shows encouraging potential of these tools to hard turning.
The calculated total machining cost per part is only Rs. 3.17 due to higher tool life (47 min at their optimal level) of multilayer TiN coated carbide insert.
The wear behaviour of the cutting edge radii manufactured by honing, in comparison to the corresponding ones by means of micro-blasting, is significantly enhanced, whereas the cutting edge radius increasing can lead to a higher tool life.
It has been observed that the total machining cost per part using CVD multilayer TiN/TiCN/Al2O3/TiN coated carbide inserts is nearly $0.13 (i.e. in Indian rupees Rs. 8.21) based on a single cutting edge under optimum cutting conditions (v = 220 m/min, f = 0.087 mm/rev and d = 0.52 mm) resulting higher tool life (39 min), magnificent for hard turning applications.
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Metallic Bonded Diamond Stones (Dia-M) are more and more used for their wear resistance and their high tool life.
Process security and preparation quality as well as a sufficiently high tool life demand for the development of hard coatings with reduced seizure tendency, high hot hardness, and increased wear resistance especially under dry machining conditions.
Only by the use of higher coolant pressures, the tool life could be significantly increased, as well as the bore quality.
In continuous high-speed turning operations the high temperature hardness is paramount and coatings with high hot hardness display longer tool life.
For interrupted cutting the plasticity index is critical, with high values (i.e. not extremely high H/E) resulting in extended tool life.
A higher rate of wear progression and lower tool life was observed at the higher cutting speed level of 229 m/min.
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