Title: A dual-layer approach for enhancing the tribological and machining performance of carbide tools in dry turning of mild-steel alloy

Authors: Kaleem Ahmad Najar; Sheikh Nazir Ahmad; M.A. Shah; Zahid Mushtaq; Sobura Altaf

Addresses: Mechanical Engineering Department, IOT Zakura, University of Kashmir, India ' Mechanical Engineering Department, NIT Srinagar, India ' Special Laboratory for Multifunctional Nano-materials, NIT Srinagar, India ' Mechanical Engineering Department, NIT Srinagar, India ' Mechanical Engineering Department, University of Kashmir, India

Abstract: Under heavy turning parameters the ordinary-carbide cutting inserts generally remain unsuccessful in the proper machining of Fe-based alloys. The present research revealed that the diamond coated-carbide tools are being considered as the best option among other hard cutting tools operating under drastic machining parameters. Since fabricating the nanocrystalline diamond (NCD) or microcrystalline diamond (MCD) mono-layers on carbide inserts is not enough to improve their overall experimental performance. Therefore, the duallayer diamond coating (DDC) was fabricated on surface modified tungsten carbide (WC-Co) inserts by connecting the films of NCD and MCD. The cutting performance was analysed on the diamond coated- and ordinary-tungsten carbide (WC-Co) inserts under unlubricated test conditions utilising a modern CNC lathe machine. The obtained experimental results confirmed that the dual-layer diamond coated-carbide tool shows superior mechanical and machining performances as compared to ordinary-one, operating within the same cutting parameters.

Keywords: carbide tool; DDC; friction; hardness; mild-steel; turning; tool wear; BUE; adhesion; tool life.

DOI: 10.1504/IJMMM.2022.122784

International Journal of Machining and Machinability of Materials, 2022 Vol.24 No.1/2, pp.132 - 148

Received: 04 Oct 2021
Accepted: 19 Nov 2021
Published online: 10 May 2022 *

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