Performance analysis of Ti2AlN superimposed WC cutting tool

This article presents the development of superimposed Ti2AlN MAX phase coatings on cutting tools through reactive co-sputtering technique in dry machining of Ti-6Al-4 V. The effect of varying nitrogen flow rate during the reactive co-sputtering process and its influence on cutting properties has also been discussed. The predictive modeling along with validation of experimental results were carried out using response surface methodology (RSM) and optimized condition for cutting force were obtained using composite desirability function. Machining studies using the superimposed Ti2AlN coatings reduced the cutting force by 23-35 % when compared to commercial coatings. Investigation of cutting mechanics revealed an increase of shear angle by 3-5 % and decrease in friction angle by 20 %. The superimposed MAX phase coatings also reduced the friction coefficient by 34 % during dry turning of Ti-6Al-4 V. The superimposed Ti2AlN coatings were held responsible to improve the performance of the tool by 21-30 % in terms of tool life when compared to commercial tool. It could be inferred that the superimposed Ti2AlN coatings reduced the effect of chemical affinity between the tool and workpiece, eliminating the formation of built-up edge at rake face of the tool.