Skip to main content
Springer Nature Link
Log in

Influence of the residual stress state of coatings on the wear behavior in external turning of AISI 4140 and Ti–6Al–4V

  • Tooling
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

The residual stress state of coatings influences tool life and performance in machining significantly. Due to thermo-mechanical loads during the cutting process the coatings require tailored properties. Beside the coating structure the two most important properties are the residual stress state and the chemical composition of the coating. Therefore, the influence of these two properties is investigated in this study, comparing the cutting performance in continuous and interrupted cutting of 42CrMo4 (AISI 4140) and Ti–6Al–4V. It is shown that the residual stress states of the coating close to the surface and close to the substrate are important for the wear behavior. High compressive residual stresses near the substrate combined with a material-optimized composition increase the resistance against chipping. Flank wear resistance increases with high compressive residual stresses near the surface and decreasing stresses towards the substrate.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Rodriguez RJ, Garcia JA, Medrano A et al (2002) Tribological behaviour of hard coatings deposited by arc-evaporation PVD. Vacuum 67:559–566

    Article  Google Scholar 

  2. Denkena B, Biermann D (2014) Cutting edge geometries. CIRP Ann Manuf Technol 63:631–653

    Article  Google Scholar 

  3. Posti E, Nieminen I (1989) Influence of coating thickness on the life of TiN-coated high speed steel cutting tools. Wear 129:273–283

    Article  Google Scholar 

  4. Bouzakis KD, Hadjiyiannis S, Skordaris G et al (2004) The effect of coating thickness, mechanical strength and hardness properties on the milling performance of PVD coated cemented carbide inserts. Surf Coat Technol 177–178:657–664

    Article  Google Scholar 

  5. Denkena B, Breidenstein B (2007) Residual stress and cohesive damage of PVD-coated carbide cutting tools. In: Proceedings of the 6th international conference THE coatings in manufacturing engineering, Hannover, pp 33–42

  6. Denkena B, Breidenstein B, Gerdes L (2008) Residual stress depth distributions in uncoated, PVD coated and decoated carbide cutting tools. In: Proceedings of the 7th international conference THE coatings in manufacturing engineering, Kallithea-Chalkidiki, Greece, pp 29–33

  7. Klocke F, Gorgels C, Stuckenberg A, Bouzakis E (2010) Qualification of coatings to predict wear behaviour of micro blasted cutting tools. Key Eng Mater 438:23–29

    Article  Google Scholar 

  8. Soroka OB, Klymenko SA, Kopeikina MY (2010) Evaluation of residual stresses in PVD-coatings, Part 2. Strength Mater 42(4):450–458

    Article  Google Scholar 

  9. Breidenstein B, Denkena B (2013) Significance of residual stress in PVD-coated carbide cutting tools. CIRP Ann Manuf Technol 62:67–70

    Article  Google Scholar 

  10. Vogli E, Tillmann W, Selvadurai-Lassl U et al (2011) Influence of Ti/TiAlN-multilayer designs on their residual stresses and mechanical properties. Appl Surf Sci 257:8550–8557

    Article  Google Scholar 

  11. Totten GE, Howes MAH, Inoue T (2002) Handbook of residual stress and deformation of steel. ASM International, Materials Park, OH

    Google Scholar 

  12. Sprute T, Tillmann W, Grisales D et al (2014) Influence of substrate pre-treatment on residual stresses and tribo-mechanical properties of TiAlN-based PVD coatings. Surf Coat Technol 260:369–379

    Article  Google Scholar 

  13. Bemporad E, Sebastiani M, Casadei F, Carassiti F (2007) Modelling, production and characterisation of duplex coatings (HVOF and PVD) on Ti–6Al–4V substrate for specific mechanical applications. Surf Coat Technol 201:7652–7662

    Article  Google Scholar 

  14. Ali R, Sebastiani M, Bemporad E (2015) Influence of Ti–TiN multilayer PVD-coatings design on residual stresses and adhesion. Mater Des 75:47–56

    Article  Google Scholar 

  15. Genzel C (1999) Entwicklung eines Mess-und Auswerteverfahrens zur röntgenographischen Analyse des Eigenspannungszustandes im Oberflächenbereich vielkristalliner Werkstoffe. Postdoctoral Lecture Qualification, Humboldt Universität Berlin

  16. Erkens G, Vetter J, Müller J et al (2011) Plasma-assisted surface coating. Süddeutscher Verlag onpact GmbH, München

    Google Scholar 

  17. Khrais SK, Li YJ (2007) Wear mechanisms and tool performance of TiAlN PVD coated inserts during machining of AISI 4140 steel. Wear 262:64–69

    Article  Google Scholar 

  18. Choo SH, Lee S, Golkovski MG (2000) Effects of accelerated electron beam irradiation on surface hardening and fatigue properties in an AISI 4140 steel used for automotive crankshaft. Mater Sci Eng A 293:56–70

    Article  Google Scholar 

  19. Lütjering G, Williams JC (2007) Titanium. Engineering materials and processes, 2nd edn. Springer, Berlin, Heidelberg, New York

  20. Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability—a review. J Mater Process Technol 68:262–274

    Article  Google Scholar 

  21. Chang YY, Lai HM (2014) Wear behavior and cutting performance of CrAlSiN and TiAlSiN hard coatings on cemented carbide cutting tools for Ti alloys. Surf Coat Technol 259:152–158

    Article  Google Scholar 

  22. Meixner M, Klaus M, Genzel C (2013) Sin2ψ-based residual stress gradients analysis by energy-dispersive synchroton diffraction constrained by small gauge volumes. II. Experimental implantation. J Appl Crystallogr 46:619–627

    Article  Google Scholar 

  23. Nouari M, Molinari A (2005) Experimental verification of a diffusion tool wear model using a 42CrMo4 steel with an uncoated cemented tungsten carbide at various cutting speeds. Wear 259:1151–1159

    Article  Google Scholar 

  24. Denkena B, Köhler J, Rehe M (2012) Influence of the honed cutting edge on tool wear and surface integrity in slot milling of 42CrMo4 steel. Procedia CIRP 1:190–195

    Article  Google Scholar 

  25. Sun S, Brandt M, Palanisamy S, Dargusch MS (2015) Effect of cryogenic compressed air on the evolution of cutting force and tool wear during machining of Ti–6Al–4V alloy. J Mater Process Technol 221:243–254

    Article  Google Scholar 

  26. Zhang S, Li JF, Deng JX, Li YS (2009) Investigation of diffusion wear during high-speed machining Ti–6Al–4V alloy with straight tungsten carbide tools. Int J Adv Manuf Technol 44:17–25

    Article  Google Scholar 

  27. Uhlmann E, Reimers W, Byrne F, Klaus M (2010) Analysis of tool wear and residual stress of CVD diamond coated cemented carbide tools in the machining of aluminium silicon alloys. Prod Eng Res Dev 4:203–209

    Article  Google Scholar 

  28. Cotterell M, Byrne G (2008) Dynamics of chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V. CIRP Ann Manuf Technol 57:93–96

    Article  Google Scholar 

  29. Sun S, Brandt M, Dargusch MS (2009) Characteristics of cutting forces and chip formation in machining of titanium alloys. Int J Mach Tools Manuf 49:561–568

    Article  Google Scholar 

  30. Franz R, Mitterer C (2013) Vanadium containing self-adaptive low-friction hard coatings for high-temperature applications: a review. Surf Coat Technol 228:1–13

    Article  Google Scholar 

  31. Breidenstein B, Bergmann B, Denkena B et al (2014) Interdependencies of residual stresses and process parameters with respect to tool life in turning of AISI 1045. In: Proceedings of the 11th international conference “THE-A” coatings in manufacturing engineering, Thessaloniki, pp 149–158

Download references

Acknowledgments

The authors would like to thank the German Research Foundation for the financial support for this work within the project “Applikationsspezifisches Design von PVD-Beschichtungen für Zerspanwerkzeuge” (BR 2967/5-1).

Author information

Authors and Affiliations

  1. Institute of Production Engineering and Machine Tools (IFW), Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    B. Breidenstein, B. Denkena & B. Richter

  2. Oerlikon Metaplas GmbH, Am Boettcherberg 30-38, 51427, Bergisch Gladbach, Germany

    J. Vetter

Authors
  1. B. Breidenstein
    View author publications

    You can also search for this author inPubMed Google Scholar

  2. B. Denkena
    View author publications

    You can also search for this author inPubMed Google Scholar

  3. J. Vetter
    View author publications

    You can also search for this author inPubMed Google Scholar

  4. B. Richter
    View author publications

    You can also search for this author inPubMed Google Scholar

Corresponding author

Correspondence to B. Richter.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Breidenstein, B., Denkena, B., Vetter, J. et al. Influence of the residual stress state of coatings on the wear behavior in external turning of AISI 4140 and Ti–6Al–4V. Prod. Eng. Res. Devel. 10, 147–155 (2016). https://doi.org/10.1007/s11740-015-0650-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-015-0650-7

Keywords