Effect of arc deposition and high power impulse magnetron sputter coatings on the performance of tools for machining various ferrous materials and Ti6AL4V alloys

In this thesis, the performance of different coating techniques in machining various steels and Ti6Al4V is investigated. Currently, most of the carbide tools with the coating because of the tool life. In order to increase the productivity of the manufacturing processes and to use new materials, the research on the coating of cutting tools has been increased. Recently, the interest in physical vapor deposition has increased because the tool life is increased for many difficult-to-machine materials and difficult machining conditions. Two types of PVD coating were used in this work. The surfaces of the coated tools were examined under scanning electron microscope. The effects of cathodic arc deposition and high pulse magnetron sputtering on tool performance were investigated on various workpieces such as 4140 and CK45 steels, D2 tool steel (60HRC), GG25 cast iron and also on Ti6Al4V alloy. In the performance tests, the cutting forces were measured over a period of time and the wear patterns were recorded. The results indicate that HIPIMS coated tools perform better in operations where normal load is low and torsion forces are high. Those tools also work better in materials harder than 250 BHN. The better performance of HIPIMS coated tools were attributed to their less smooth and droplet free surfaces.