Journal of Materials Processing Technology 176 (2006) 102110

Composite layer-based analytical models for toolchip interface temperatures in machining medium carbon steels with multi-layer coated cutting tools
W. Grzesik
Department of Manufacturing Engineering and Production Automation, Technical University of Opole, P.O. Box 321,45-271 Opole, Poland Received 6 April 2004; accepted 20 February 2006

Abstract This investigation is devoted to the thermal problems in dry orthogonal turning of a C45 medium carbon steel with natural contact tools treated with multi-layer coatings with an intermediate Al2 O3 layer. New hybrid analytical models for estimating heat partition to the chip and the toolchip interface temperatures were proposed. Furthermore, the physics-based modelling concept, which applies composite layer approach was developed to estimate the average and maximum steady-state toolchip interface temperatures in orthogonal turning. The model predictions were compared to appropriate experimental process data using natural tool-work thermocouples and other simulated and measured literature data. It was veried that the models proposed yield accurate average temperatures and estimate their maximum values for uncoated and two multi-layer coated tools for cutting speeds ranging from 90 to 240 m/min. 2006 Elsevier B.V. All rights reserved.
Keywords: Machining; Coated carbides; Interface temperature; Analytical modelling

1. Introduction The often used combination of higher cutting speeds (HSC) with dry process conditions and demands on high performance cutting (HPC) require cutting tools with special heat-protected coatings due to severe tribological inuences [1,2]. In order to improve the heat isolating effect multi-layer coatings have rst been synthesized to combine the benecial properties of various ceramic materials, such as TiC, TiN, TiCN and Al2 O3 [3,4]. Another trend observed is the transition to complex and more wear-resistance CVD-Al2 O3 -based coatings with controlled deposition of -Al2 O3 or -Al2 O3 . At present, TiAlN plays an increasingly important role in the design of advanced PVD coatings. The excellent performance of commercially available TiAlN coated tools, conrmed by a great number of published experimental data, results from the higher hot hardness and oxidation resistance of these hard materials at elevated temperatures [3,5]. Moreover, improved TiAlCrN or TiAlCrYN coatings, including multi-layering with CrN and incorporation

Tel.: +48 77 4006290; fax: +48 77 4006342. E-mail address: grzesik@po.opole.pl.

of yttrium, signicantly outperform the commercial ones [6]. Recently, the metastable solution phase (Ti,Al)N in cubic NaCl (B1) structure, named as supernitrides, with a superior oxidation resistance and hardness under both dry and high speed (up to 600 m/min) machining conditions has been launched [7]. It is clear that the determination of the exact temperature rise in the toolchip interface has been recognized as an important study in achieving the best cutting performance. For the above reason, an estimation of the heating and temperature histories on the rake face of cutting tools is necessary. Another approach is to assess the steady-state temperatures (average and maximum temperature responses) developed rapidly at the rst stage of machining. In this case study the steady-state temperature problem was solved in such a way that heat ux components and heat partitioning are estimated by minimizing the difference between the modelled and the corresponding measured temperatures. In particular, a few different formulae for the heat partition coefcient for sliding bodies with dened thermal properties and the composite (equivalent) layer concept are employed. In practice, the two characteristic values of the interface temperature allow to evaluate prevailing sources of the tool failure, i.e. presumable reduction of its hardness resulting from the thermal

0924-0136/$ see front matter 2006 Elsevier B.V. All rights reserved. doi:10.1016/j.jmatprotec.2006.02.025

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softening effect [2] and the occurrence of temperature-activated wear mechanisms [4]. 2. Modelling concept 2.1. Thermal properties of the tool and workpiece materials Numerous approaches have been proposed to model metal cutting temperature with various degrees of success. Along with a laborious experimental approach, several numerical and analytical techniques have been proposed to model the temperature proles. Another important question posed lately by Davies et al. [8] is to distinguish between prediction and interpreting machining temperatures. This paper rst describes the recently developed analytical method for predicting interface temperatures since multi-layer coating is modelled as a uniform stack of layers with temperature-dependent equivalent thermal properties. Recently, a composite coating layer approach has been proposed for simulation of such process outputs as the chip geometry, cutting forces and steady-state tool temperature [9]. In the composite layer concept, in which all components are represented by one homogeneous thick layer, the equivalent (effective) thermal conductivity depends on the thickness of each component and the number of coating layers. It can be determined using the well known in thermodynamics expression [10], as follows:
t 1 xi

Fig. 1. Equivalent thermal conductivity vs. temperature. 3L, TiC/Al2 O3 /TiN; 4L, TiC/TiCN/Al2 O3 /TiN.

eq

x1 x2 xt = + + + 1 2 t

(1)

Al2 O3 layer, and two composite structures considered are shown in Fig. 2. 2.2. Determination of the heat partition coefcient For the modelling purpose, three different methods of calculation of the heat partition coefcient are used, namely those proposed by Shaw-RSH [11], Kato and Fujii-RKF [12], and Reznikov-RR [13]. The value of RSH coefcient can be estimated as: RSH = 1 1 + [0.754(Teq /W )/Aa NT ] (3)

where xi is the thickness of the selected i-layer (in this case i = 3 and 4), i the thermal conductivity of i-layer, xi the total thickness of the stack (composite layer) and eq is the equivalent thermal conductivity of the total layer, t denotes the top layer. Fig. 1 presents values of the thermal conductivity for composite layers equivalent to TiC/Al2 O3 /TiN and TiC/Ti(C,N)Al2 O3 /TiN multi-layer coatings. As can be seen from Fig. 1 both aggregate thermal properties represented by courses 3L and 4L change similarly to an Al2 O3 ceramic layer, but the effect of reduction of thermal conductivity is more pronounced for four-layer coatings due to the thicker ceramic layer. This effect explains the previously reported substantial reduction of the toolchip interface temperature when using these coatings as a heat isolation for the carbide substrate [3]. The equivalent diffusivity can be determined as the ratio of the equivalent thermal conductivity to the equivalent volumetric heat capacity (Ceq ). The proper formula can be derived by summing volumes of the individual layers Vi to obtain the total coating, as follows: Ceq = eq =
t 1 (xi cpi i ) t 1 xi

t 1 (xi Ci ) t 1 xi

(2a) (2b)

eq Ceq

where Ci , cpi and i are the volumetric heat capacity, the specic heat and density of i-layer, respectively. The computed values of the equivalent diffusivity eq for the temperature rise within the range of 4001000 C for a single

Fig. 2. Thermal diffusivity vs. temperature. 3L, TiC/Al2 O3 /TiN; 4L, TiC/TiCN/ Al2 O3 /TiN.

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In Eq. (3) thermal conductivities of work (W ) and tool (T = Teq ) materials, thermal number (NT ) and area shape factor (A) describe the thermal and geometrical features of the interface. Adequate formulae for NT and A are provided in [13]. The expression proposed by Kato et al. [12] was originally dened for conventional surface grinding and in this study modied version is used as follows: 1 RKF = (4) 1 + (Ceq eq )T /(cp )W It should be noted that in Eq. (4) the heat transmission ratio (triple product, cp ), dened for work (W) and tool (T) materials is introduced. On the other hand, coefcient RR takes into account the velocity and duration of frictional heat source in terms of both Peclet and Fourier numbers [13]. In the version proposed Eq. (5) includes optionally thermal conductivities (T = Teq and W ) and diffusivities (T = Teq and W ) of both coupled materials. Then the adequate expression can be given by RR = 1 1 + [(3Teq /2W ) W /Teq ] (5)

where Teq is the equivalent thermal conductivity of the composite layer and Teq is corresponding thermal diffusivity. 2.3. Determination of interface temperature increments In general, the modelling concept proposed is based on the well-known principle that the total heat ux (q) is generated by aggregating the plastic deformation and sliding friction effects. The main difference from other existing models is that it incorporates actual values of the thermal properties and heat partition coefcients as a function of temperature in one comprehensive model. According to Shaw [11] the temperature increment due to the action of the frictional heat source (lc is the toolchip contact length) can be determined as: 0.377Rqlc f = W N T (6)

For the maximum rise of the interface temperature f max constant in Eq. (6) is equal to 0.565. Maximum temperature at the

Fig. 3. Flow chart for prediction the heat partition coefcient and peak and average toolchip interface temperatures.

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shear plane can be computed as: smax = sh erf cp tan R tan 4 (7)

By analogy, the maximum interface temperature is the effect of proper temperature peaks, namely: max = s max + f max (10)

where sh is the shear ow stress, the shear angle and R is the thermal number dened by Boothroyd [14]. Computations of the mean temperature at the shear plane are based on the theory of similarity elaborated for metal cutting purpose by Silin [15]. In this study the values of s were determined for three characteristic ranges of the product R tan as follows: for R tan 5, s = 0.685(R tan )0.07 s max (8a)

Flow chart describing ve characteristic steps of the computational procedure is shown in Fig. 3.
3. Experimental data
In this study, the measured data concern turning experiments with two CVD-multi-layers with an intermediate ceramic layer, namely: TiC/Al2 O3 /TiN and TiC/Ti(C,N)/Al2 O3 /TiN coated at-faced inserts consisting of ISO P20 cemented carbide substrate. The thicknesses of individual layers including in these two multi-layer structures, given by the manufacturerSandvik Baildonit, Poland, are (6 + 3 + 1) m and (4 + 2 + 6 + 1) m, respectively. The tools were commercial grade inserts. The ISO TNMA 160408 style inserts with a working clearance angle equal to 7 and the corresponding negative rake angle of 7 were selected. The orthogonal dry cutting tests were carried out on a precision lathe using a thin-walled tube workpiece. The thickness of the tube wall was equal to 2 mm and its outer diameter was set at 80 mm. The test inserts were evaluated in the turning of C45 (AISI 1045) medium carbon steel. During tests the following cutting parameters were selected: the cutting speed vc = 90240 m/min, feed rate f = 0.16 mm/rev, the depth of cut ap = 2 mm. The measuring and processing techniques for the cutting forces and the thermal EMF signals, and the toolchip contact area and its length were essentially similar to those used in previous authors studies on cutting tool coatings [2,16] and will not be repeated here. Overall scheme of the measurements and computations performed during and after the experiments is illustrated in Fig. 4.

for 5 R tan 20, for R tan 20,

s = 0.620(R tan )0.13 s max (8b) (8c)

s = 0.820(R tan )0.04 s max

The average interface temperature is dened as the sum of the mean shear-plane temperature (s ) and the mean temperature f ), namely: rise due to friction ( t = s + f (9)

Fig. 4. Scheme of measurements and computations during the experiment.

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Fig. 5. (a) Structure (SE image) of carbide substrate and components of four-layer coatings. Magnication: 3500. (b) Structure (BE image) of substrate/coating system with thicknesses of the individual layers shown in Fig. 5a. Magnication: 3500. In order to store the data in the computer memory, on-line measurements were accomplished by a multi-channel data acquisition software. Despite typical metal cutting measurements depicted in Fig. 4, some specic measurement methods which are preferentially applied to reveal the coating morphology and its chemical composition and to measure the thicknesses of individual layers are employed. In this part of investigation a scanning electron microscope Philips XL 20 equipped with an EDAX analyser was used. The operating conditions during SEM analysis were 20 kV voltage and summing time of 50 s. Special attention, due to the necessity of precise determination of the equivalent thermal properties, was given to the thickness measurements by a standard SEM at a polished fracture cross-section of the coated sample shown in Fig. 5a and b. The thicknesses of individual layers were determined on the images created by the backscattered electrons (BE), as shown in Fig. 5b. It can be concluded that the measured values of layer thicknesses can differ substantially from those provided by manufacturers in catalogues. For example, the measured thickness of the TiN top layer is about 330 nm (0.33 m), whereas that found in catalogue is equal to 1 m. Additionally, the energy-dispersive Xray analysis (EDX) was used to determine elemental spectra of various coating layers (a Ti(C,N) underlayer, an Al2 O3 intermediate layer and a TiN outerlayer) as presented in Fig. 6ac, respectively. This analysis reveals that the underlayer

Fig. 6. (a) Spectrum and chemical composition of a TiN outerlayer from Fig. 5a. (b) Spectrum and chemical composition of an Al2 O3 intermediate layer from Fig. 5a. (c) Spectrum and chemical composition of a TiCN/TiN underlayer from Fig. 5a.

W. Grzesik / Journal of Materials Processing Technology 176 (2006) 102110 includes also a small amount of titanium nitride (TiN) and tungsten carbide (WC) at the coating/cemented carbide interface, which has diffused from the substrate during the high temperature CVD deposition.

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4. Results and discussion The results of computations carried out in this investigation are successively shown in Figs. 713. The presentation scheme used in Figs. 810 includes comparisons between measured values of the interface temperatures and average temperature rise computed for different heat partitioning models. In these three cases concerned, uncoated (Fig. 8), three-layer coated (Fig. 9) and four-layer coated (Fig. 10) tools, the predicted total average

Fig. 9. Average interface temperatures vs. cutting speed. 1, measurements; predictions: 2, using Eq. (3); 3, using Eq. (4); 4, using Eq. (5). Tool material: TiC/Al2 O3 /TiN coating.

temperature rise was calculated from Eq. (9). Furthermore, this prediction was extended to the maximum interface temperatures obtained from Eq. (10). 4.1. Assessment of heat partitioning Fig. 7 shows changes of the heat partition coefcient computed for multi-layer coated tools (courses 3L and 4L) when machining C45 carbon steel. Computations were based on the assumption of composite layer using RR , RKF and RSH partition coefcients represented by cases A, B and C, respectively.

Fig. 7. Heat partition coefcient vs.cutting speed. A, RR ; B, RKF ; C, RSH . 3L, TiC/Al2 O3 /TiN; 4L, TiC/TiCN/Al2 O3 /TiN.

Fig. 8. Average interface temperatures vs. cutting speed. 1, measurements; predictions: 2, using Eq. (3); 3, using Eq. (4); 4, using Eq. (5). Tool material: ISO P20 sintered carbide.

Fig. 10. Average interface temperatures vs. cutting speed. 1, measurements; predictions: 2, using Eq. (3); 3, using Eq. (4); 4, using Eq. (5); 4a, corrected curve #4. Tool material: TiC/Ti(C,N)/Al2 O3 /TiN coating.

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Fig. 11. Components of average interface temperature vs. cutting speed. 1, 89 m/min; 2, 103 m/min; 3, 144 m/min; 4, 178 m/min; 5, 206 m/min; 6, 237 m/min.

Fig. 13. Comparison between predicted and measured interface temperatures when varying cutting speed. Symbolics: av, average; max, maximum; m, measurement. 1, ISO P20; 2, TiC/Al2 O3 /TiN; 3, TiC/TiCN/Al2 O3 /TiN.

It was found that for the model proposed the heat partition coefcient calculated from Shaws version (case C) is higher than 0.9 when using multi-layer coated tools like for uncoated carbide tools and it increases slightly with the cutting speed rise up to the maximum value of about 240 m/min. In contrast, when using the RR value, 0.550.61 of the dissipated heat ows to the chip depending on the coating used. This implies that the use of multi-layer coated tools can cause that at most about 40% of heat generated during the cutting process at higher cutting speeds is transferred into the tool body. As shown in [13] in such cases the substantial change of the heat partition coefcient observed for the maximum cutting speed applied reduces the interface temperature for multi-layer coatings with an intermediate Al2 O3 ceramic layer from 700 to 630 C.

4.2. Determination of temperature components Figs. 811 show the summing effect of the friction and shearing components of the interface temperature. The predicted values of the components of the average interface temperature obtained for the P20 cemented carbide tools are shown in Fig. 8. In this case, the best prediction was achieved when the heat partition was estimated by means of the classical Shaws formula (Eq. (3)) and the temperature increment resulting from the sliding friction was computed using Eq. (6). On the other hand, for the three-layer coating (Fig. 9) and also for four-layer lm tested (Fig. 10) the resulting temperature values t the measured ones reasonably well when using the combination of Eqs. (6) and (5) (in Figs. 9 and 10 the best predictions for both multi-layer coatings were denoted by course #4). In particular, this coincidence improves distinctly for the cutting speed higher than 100 and 120 m/min for three- and four-layer coatings, respectively, but it is quite perfect for uncoated tools and the cutting speed ranging from 100 to 200 m/min. In all cases considered the prediction accuracy oscillates between 5% and +10%, but for uncoated and three-layer coated tools and the cutting speeds of above 120 m/min reaches even 2.5%. In addition, Fig. 10 includes the corrected temperature prediction denoted as 4a, which accounts for measured thicknesses of individual layers involved in the four-layer coating provided in Fig. 5b. It can be observed in Fig. 10 that for the thermal model used the predicted values of the average interface temperature are not sensitive to the dimensional correction of multi-layer structure. Depending on the cutting speed applied the corrected temperatures overestimate slightly (from 0.5% to 1%) ones computed with the nominal thicknesses (expressed in full micrometers) of individual layer given by insert manufacturer. The predicted average temperature along the toolchip interface for different cutting speeds is shown in Fig. 11. It can be seen that a higher temperature is reached along the toolchip

Fig. 12. Components of maximum interface temperature vs. cutting speed. 1, 89 m/min; 2, 103 m/min; 3, 144 m/min; 4, 178 m/min; 5, 206 m/min; 6, 237 m/min.

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interface when the uncoated tools were used. As documented in Fig. 11 substantially lower temperature rises generated by friction at the secondary deformation zone (SDZ) are observed for multi-layer coatings. Under experimental conditions used, adequate differences dealing with the reduction of friction are in the range of 50175 C depending on the cutting speed. On the other hand, the temperature rises due to shearing in the primary deformation zone (PDZ) were found to be, in general, slightly higher than for uncoated tools. By analogy to the distinction between the components of the average interface temperature shown in Fig. 11, the bar diagram in Fig. 12 provides the differences between the computed maximum and average values of temperatures (upper shaded fractions of bars) for six selected cutting speeds. It can be seen in Fig. 12 that on average the top interface temperatures were assessed to be higher about 220250 and 170200 C for uncoated P20 and multi-layer coated tools, respectively, than the average temperatures predicted for the same cutting conditions. 4.3. Comparison between predictions and measurements

f = 0.15 mm/rev), measured by means of the IR-CCD camera technique was set at max = 987 C. In comparison, Fig. 12 (bar #5) displays the corresponding temperature predicted (vc = 200 m/min, f = 0.16 mm/rev) to be equal to 1015 C. Moreover, the results of FE simulation using NASTRAN solver on carbide tool and SAE 1018 mild carbon steel for cutting speed of vc = 135.6 m/min (f = 0.2 mm/rev, ap = 2.54 mm and r = 0.8 mm, included insert angle = 90 ), presented in [17], have yielded the values of average and peak temperatures of 708 and 834 C, respectively. On the other hand, it was revealed in this study that the nite element model results in good agreement with the analytical solution using Loewen and Shaws equations for a sharp rectangular insert [20] both in the trend and the absolute values. Similarly, the methodology developed allows to predict for uncoated carbide tools the rake face average and peak temperatures (vc = 135 m/min, f = 0.16 mm/rev) of 690 and 926 C, respectively. The differences between both methods are primarily due to combination of experimental (measuring) errors and the assumption of the analytical/nite element models. 5. Conclusions

Calculation results dealing with the average and maximum interface temperatures obtained for uncoated and coated tools are completely shown in Fig. 13. It should be noted that for uncoated P20 carbide tools the maximum interface temperature ranges from 860 to 1085 C depending on the cutting speed employed. On the other hand, the peak temperature changes from 755 to 830 and 750 to 800 C for three- and four-layer coatings, respectively. For comparison, the average interface temperature for the couple of multi-layers used increases from 560 to 660 and 550 to 630 C, respectively. A better accuracy of average temperature modelling is observed for uncoated carbide tools within the medium speed range and for multi-layer coatings within high speed range in Fig. 13. Quantitatively, the predicted average and maximum toolchip interface temperatures agree well with appropriate temperature predictions by means of nite element modelling (FEM) simulations provided in [9] and [17] and IR-CCD tool measuring system [18]. Yen et al. [9] have predicted the tool temperature using the a commercial FEM code DEFORM-2D with emphasis on the thermal inuence of multiple coatings. In this study, the coated tools consisting of cemented WC-Co substrate deposited with three coating layers: 6- m TiC/3- m Al2 O3 /1m TiN were tested versus workpiece material AISI 1045. In the case of composite layer concept, the predicted steady-state average interface temperature for cutting speed vc = 220 m/min and feed rate f = 0.16 mm/rev was about 682 C. The predicted result is in good agreement with the thermocouple experiment (655 C) and analytical model (660 C) within 4% overestimation. As suggested, this inconsistency can be attributed to the material stress model which provides cutting forces signicantly larger (even above 24%) than the experimental ones. It is worth noticing that the validation of FEM-based simulation results was done using the authors data published in paper [19]. MSaoubi and Chandrasakaran [18] have reported that the maximum temperature at the toolchip interface for SS2541 steel and P20 (S6) carbide grade (vc = 200 m/min,

i. The present study revealed that analytical models can also be favoured for the modelling of cutting temperatures because they can give much more insight in the contribution of plastic deformation and friction to the thermal behaviour in metal cutting. ii. As a result of composite layer-based modelling, new computational algorithm for predicting both the average and peak values of the interface temperatures with relatively high accuracy at the cutting speeds ranging from 90 up to 240 m/min is proposed. iii. The composite layer model for three-layer coating is in good agreement with both the experimental data and FEM predictions within 4% difference. iv. Results are highly dependent on providing accurate models for the heat partitioning and friction behaviour. It was revealed from this modelling that for specially tailored multilayer lms the partition coefcient can be increased even above 0.6. v. An intriguing issue being examined is that an increment of the average interface temperature produced by sliding friction for medium carbon content steel, such as C45 steel, and multi-layer coatings is distinctly lower than for uncoated carbide tools. vi. It can also be important for practice that the maximum interface temperatures predicted can support the choice of coated inserts for dened machining parameters in order to avoid excessive thermal loading of the tool. Acknowledgments The author would like to thank prof. S. Krol from Department of Materials Engineering, TU Opole, for providing SEM images and EDA data and their professional analysis and Dr. P. Nieslony for computing the temperatures by means of various analytical models.

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W. Grzesik / Journal of Materials Processing Technology 176 (2006) 102110 [10] F.P. Incropera, D.P. De Witt, Fundamentals of Heat and Mass Transfer, Edward Arnold, London, UK, 1990. [11] M.C. Shaw, Metal Cutting Principles, Clarendon Press, Oxford, UK, 1989. [12] T. Kato, H. Fujii, Energy partition in conventional surface grinding, ASME J. Manufact. Sci. Eng. 121 (1999) 393398. [13] W. Grzesik, P. Nieslony, A computational approach to evaluate temperature and heat partition in machining with multi-layer coated tools, Int. J. Mach. Tools Manufact. 43 (2003) 13111317. [14] G. Boothroyd, W.A. Knight, Fundamentals of Machining and Machine Tools, Marcel Dekker, New York and Basel, 1989. [15] S.S. Silin, Similarity Methods in Metal Cutting, Mashinostroenie, Moscow, 1981 (in Russian). [16] W. Grzesik, The role of coatings in controlling the cutting process when turning with coated indexable inserts, J. Mater. Proc. Technol. 79 (1998) 133143. [17] A.U. Anagonye, D.A. Stephenson, Modeling cutting temperatures for turning inserts with various tool geometries and materials, ASME J. Manufact. Sci. Eng. 124 (2002) 544552. [18] R. MSaoubi, H. Chandrasakaran, Investigation of the effects of tool micro-geometry and coating on tool temperature during orthogonal turning of quenched and tempered steel, Int. J. Mach. Tools Manufact. 44 (2004) 213224. [19] W. Grzesik, An integrated approach to evaluating the tribo-contact for coated cutting inserts, Wear 240 (2000) 918. [20] E.G. Loewen, M.C. Shaw, On the analysis of cutting-tool temperatures, Trans. ASME 76 (1954) 217231.

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