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1 2017

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A critical review of characteristic techniques for improving the cutting performance of coated tools

Bouzakis K.-D., Skordaris G., Bouzakis E., Kotsanis T., Charalampous P.

Journal of Machine Engineering

2017

Vol. 17, No. 2

25--44

The cutting performance of PVD coated tools can be significantly improved by applying optimized PVD processes, film architectures, as well as appropriate pre- and post- treatments of the substrates and coated surfaces respectively. Substrate pre-treatments aim, among others, at improving the coating adhesion. In this way, lower coating loads develop during cutting leading to a decelerated wear evolution. Furthermore, the effect of various PVD process parameters and film architectures such as of adhesive interlayers, Ar+ ions bombardment, thickness distribution and multi-layer structure on the coated tool life is demonstrated. Finally, the potential to increase the wear resistance of coated tools via micro-blasting and to render sharp cutting edges mainly of small diameter tools more stable by rounding them via grinding is presented. Micro-blasting parameters such as of grain material, pressure, dry or wet etc., affect significantly the superficial coatings’ hardness and brittleness and in this way their wear behaviour. To check the effectiveness of all these methods, innovative coating's characterization procedures providing information concerning the film and substrate properties as well as adhesion are applied, thus reducing the required experimentation time.