Analysis of Wear Mechanisms Under Cutting Parameters: Influence of Double Layer TiAlN/TiN PVD and TiCN/Al2O3 Chemical Vapor Deposition-Coated Tools on Milling of AISI D2 Steel

Tool selection is relevant because a wide variety of materials exhibit different machinability behaviors. Tool life during manufacturing is commonly associated with productivity. Insert developers have been using coatings on cutting tools to enhance their performance, with chemical vapor deposition (CVD) and physical vapor deposition (PVD) being the two most used techniques. This study analyzed the cutting tool wear mechanism by machining AISI D2 steel using two different inserts of TiAlN/TiN PVD and TiCN/Al2O3 CVD as layers deposited on a carbide substrate. The two inserts were tested at three different cutting speeds, namely, low, medium, and high; these values were below the data suggested by the supplier catalog. The flank wear and rake face were analyzed using scanning electron microscopy (SEM) and energy-dispersive X-ray spectrometry (EDX). The adhesion material, edge deformation, and abrasion were the main wear mechanisms before catastrophic damage occurred at the three different cutting speeds in the PVD cutting tool. Nevertheless, increasing the cutting speed reduced the tool life from 84% to 61% at high values compared to the medium values of PVD and CVD, respectively, where the medium value resulted in a balance between the material removal rate and tool life. The wear mechanism of the CVD tool was BUE and chipping; nevertheless, its craters were larger than those of the PVD. Compared to those configured for PVD, the CVD insert demonstrated the ability to machine D2 steel at twice the cutting speed with a workpiece surface roughness of 0.3 µm, in contrast to a variation of 0.6 to 0.15 µm with the PVD tool.