A case study on extended approach for wear analysis of TiAlCrSiN coated cutting inserts

There is an increasing demand for physical vapor deposition nanocomposite tool coatings such as TiAlCrSiN for challenging cutting operations. Here, a holistic data-driven modeling approach including coating properties, thermomechanical tool loading, comprehensive tool wear analysis and cutting process data is required for coated tool qualification. Hence, current study focuses on development of an extended tool wear analysis approach for TiAlCrSiN coated cemented carbide inserts required for model-based qualification of such tools. Monolayer TiAlCrSiN and bilayer TiAlCrSiON/TiAlCrSiN coatings were deposited on cemented carbide inserts and characterized. The wear behavior of coated variants was studied during dry turning of quenched and tempered 42CrMo4+QT alloy steel. In addition to VB measurement, an image analysis algorithm was developed to quantify the extended tool wear features with SEM images. Monolayer TiAlCrSiN, due to its higher temperature-dependent indentation hardness H IT , displayed higher abrasive wear resistance. The oxynitride top layer for bilayer variant reduced the workpiece material adhesion to the tool rake face and resultantly improved crater wear resistance of the inserts. Moreover, the qualitative observations on tool wear behavior were validated with quantitative evaluation of tool wear features and process forces. The study implemented initial steps to realize an extended quantitative tool wear analysis approach for improved understanding on wear development in PVD-coated cutting tools. • Extended quantitative wear analysis of PVD coated cutting inserts. • Reduced adhesions from steel workpiece on cutting inserts with oxynitride coating. • Increased crater wear resistance of cutting inserts with oxynitride coating. • Improved understanding on tool wear behavior using extended analysis approach.