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. 2023 Mar 22;16(6):2535.
doi: 10.3390/ma16062535.

The Study of Radius End Mills with TiB2 Coating When Milling a Nickel Alloy

Sergey Grigoriev  1 , Marina Volosova  1 , Mikhail Mosyanov  1 , Sergey Fedorov  1
Affiliations

The Study of Radius End Mills with TiB2 Coating When Milling a Nickel Alloy

Sergey Grigoriev et al. Materials (Basel). .

Abstract

Nickel alloy high-speed processing technology using ball-end mills is characterized by high contact temperature and leads to accelerated tool wear. One of the effective ways to increase its reliability and service life is to modify the surface by applying functional antifriction layers in addition to wear-resistant coatings. Diamond-like carbon is often used as the latter. However, at cutting speed, when a cutting-edge temperature exceeding 650 °C is reached, the material of this coating reacts actively with oxygen in the air, and the sharply increasing adhesive component of wear quickly incapacitates the milling tooth, limiting its performance. Applying a coating of titanium diboride as an antifriction layer on top of nanocrystalline composite nitride coatings with good resistance to abrasive wear can be a solution to this problem. Our experiments have shown that such technology makes it possible to obtain a twofold increase in durability compared to a tool with a diamond-like antifriction coating in conditions when the cutting edge of the tool is subjected to cyclic thermal shocks above 800 °C, and the durability period of the radius end mill is about 50 min.

Keywords: DLC; TiB2; abrasive and adhesive wear; ball-end mills; coatings.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
The experimental ball end mills with coatings 1—TiB2, 2—CrN−ncAlTiN/Si3N4 + TiB2, 3—CrN−ncAlCrN/Si3N4 + TiB2, 4—CrN−ncAlCrN/Si3N4 + DLC.
Figure 2
Figure 2
The milling–turning test on ball-end mills.
Figure 3
Figure 3
(a) The durability of ball-end mills with coatings: 1—uncoated, 2—TiB2, 3—CrN−ncAlCrN/Si3N4 + DLC, 4—CrN-ncAlCrN/Si3N4 + TiB2, 5—CrN-ncAlTiN/Si3N4 + TiB2. The cutting mode is shown in Table 3, the dotted line shows the value of the wear criterion; (b) the scheme of flank surface wear measure.
Figure 4
Figure 4
The wear to 0.2 mm on the flank surface cutting edge of the milling cutter tooth coated with TiB2 (a) and CrN−ncAlCrN/Si3N4+DLC (c) in reflected electrons, (b,d) distribution of chemical elements on the surface of worn-out milling cutters, respectively.
Figure 4
Figure 4
The wear to 0.2 mm on the flank surface cutting edge of the milling cutter tooth coated with TiB2 (a) and CrN−ncAlCrN/Si3N4+DLC (c) in reflected electrons, (b,d) distribution of chemical elements on the surface of worn-out milling cutters, respectively.
Figure 5
Figure 5
View of the cutting edge worn to 0.2 mm on the flank surface of the milling cutter tooth coated with CrN-ncAlTiN/Si3N4+Tab2 (a) and CrN-ncAlCrN/Si3N4 + TiB2 (c) in reflected electrons and (b,d) distribution of chemical elements on the surface of worn-out milling cutters, respectively.
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