Latest

Developments in
Cutting tools and
Coatings
SRUTI.B
18BME1190
Digital Assignment 1
MEE4001- Tool Design
CUTTING TOOLS:
Gone are the days where cutting tool inserts have to be replaced everyday due to
either breakage or other forms of failure. We have come a long way since mild
steel inserts that were highly laborious to work with and had to be monitored
carefully to ensure same milling or turning quality on every piece of the product
was made. Today’s inserts are sharp edged, smooth alloyed ingots with
temperature control and more coatings on a nano layer than one can ever
imagine. Due to these, the cost per piece machining as well as the productivity
rate is at an all-time high.
Cutting tool is a wedge shaped and sharp-edged device that is used to remove
excess layer of material from the workpiece by shearing during machining in
order to obtain desired shape, size and accuracy. It is rigidly mounted on the
machine tool. A relative velocity between workpiece and cutting tool is also
provided by various mechanical and other arrangements for cutting action.
In order to understand why there is such a plethora of innovation in this field to
provide higher levels of optimisation for the inserts, it is essential to understand
the features of a cutting tool and where perfection would lie.
Cutting tools must simultaneously withstand big mechanical loads and high
temperatures. Temperature in the chip/tool interface reaches more than 700 °C
in some cases. Additionally, the friction between tool and removed chip, on one
hand, and tool against the new machined surface, on the other, is very severe.
Bearing this in mind, the main factors for a good tool design and post-
manufacturing are:
• Cutting-tool substrate material must be very stable chemically and physically
at
high temperatures.
• Material hardness must be kept to the high temperatures suffered at the
chip/tool interface.
• Tool material has to present a low wear ratio, both for the abrasion and
adhesion
mechanisms.
• Tool material must present enough toughness to avoid fracture, especially
when
operation to perform implies interrupted or intermittent cutting.
In the following sections each of the main tool materials are going to be
described,
starting from the lowest hardness to the highest. These groups are:

• High-speed steels (HSS), including the new powder-sintered grades. However,

this material family has not enough hardness for hard machining.
• Sintered carbides, usually known as hardmetal. They are a compound of
submicron
tungsten carbide grains with a binder (usually cobalt, 6–12 %) This kind
of material in the straight grade or in the coated grades (see an example in
Figure
2.1) is the most used today for hard machining and high-speed machining.
• Ceramics based on alumina (Al2O3) or silicon nitride (Si3N4).
• Extra-hard materials, i.e., polycrystalline diamond (PCD) and polycrystalline
cubic boron nitride (PCBN), in different grades.

Bend strength versus hardness for tool materials

Current tool market two types of company are possible:

 Firstly, the producers of basic tool materials, usually big international
companies such as CeraTizit, Krupp, Sumitomo, General Electric, De
Beers, Sandvik, Kennametal, Iscar and others, which also manufacture
the complete cutting-tool systems including toolholders, inserts or
integral cutting tools. Currently these companies represent the 80 % of
the total world market.
 Secondly, there are small and medium companies that start from
calibrated material rods, supplied by some of the former companies, and
give form and geometry to cutting tools. This is the case of integral
endmills, drilling tools and tailor-made tools. The natural markets for
these companies are either very specific niches or special tailor-made
tools built with user requirements.
Latest Developments in Cutting Tools:
Earlier a tool material derived from hard metal is the cermet (ceramic–metal)
type, sintered tungsten carbide also including TiC (carbide with hardness 3200
HV) and in some cases TiCN, but they typically have a nickel–chrome binder.
Nowadays new grades with TaNbC and MoC increase the tool-edge strength
against the cyclic impacts typical of milling have been introduced.

The effect of the aluminium alloying and its extreme efficiency in machinability
of cutting tool inserts when found recently resulted not only in a greater
hardness at temperatures of up to 900 °C, but also it provided a much better
oxidation resistance up to that temperature. Both properties, hardness at high
temperatures and oxidation resistance up to 900 °C, opened a new field of
cutting conditions for the most advanced tools, meaning higher cutting speeds
and dry cutting with lifetimes comparable to cutting tools coated with TiN
working at moderate conditions with lubrication. This was a great leap for cost
saving in advanced manufacturing processes.

Sandvick:

The Sandvick company has produced a “Multidirectional Prime Turning” tool

which enables longitudinal turning to be performed feeding away from the
chuck. Lower cutting pressure during passes made away from the chuck enables
higher cut data and material removal rates during roughing. This operation also
creates thinner, wider chips and spreads the load and heat away from the nose
radius improving tool life.
Coromil 490:
The first in a new family of versatile shoulder milling tools, the CoroMill 490
will cut the cost of face and shoulder milling operations in small to medium
batch sizes.
The CoroMill 490 offers lower tool costs, reduced tool inventories, greater
flexibility, higher precision, and better tolerances. The CoroMill 490 features
four-edge inserts with outstanding geometry design and new grades. The state
of the art CoroMill 490 insert design produces less cutting force on the
component, providing better operational stability while requiring less
horsepower. This results in a smoother profile and reduces the amount of
machining time spent on finishing.
To minimize tooling inventories and operational expenses, the CoroMill 490
was designed to excel in a wide variety of milling operations. The tool can be
used for contouring and edging, semi-finish and finish boring with cylindrical or
helical interpolation, and slot milling. By providing high performance across a
spectrum of milling applications, the CoroMill 490 can replace expensive stocks
of specialized tools and simplifies production control.
The CoroMill 490 maximizes the potential of Sandvik Coromant's New Insert
Generation milling grades. Combined with unique geometries, these new grades
machine high quality component in a productive, dependable and predictable
way, while holding tight tolerances. The new edge geometry provides better
surface finishes and tighter tolerances on milled components, and good chip
evacuation.
SUMO TEC:

It features a new series of premium tungsten carbide grades to meet the

contemporary machining challenges of the metal cutting industry.
The new series of carbide grades will excel metal cutting performances to new
achievements in drilling, milling, turning, and grooving applications.
Complementing SUMO TEC, Iscar has developed a new series of tools and
inserts branded SUMO lines.
The new exclusive grades significantly extend insert tool life as a result of a
unique innovative substrate scientifically engineered by ISCAR. In addition, the
SUMO TEC grades feature the most advanced coating technology using the
CVD and PVD processes. Behind the PVD process is Iscar's AL-TEC coating
technology. The CVD coating is based on Iscar's ALPHA-TEC technology,
which has proved to be superiorly resistant to wear. This unique process
provides improved tool life, low insert surface stresses, and an evenly coated
top surface. The even surface contributes to smooth uninterrupted chip flow,
less generated heat and less friction. The new process improves toughness and
chipping resistance, thus reducing friction and built-up edge, which in turn
prolongs tool life at increased machining conditions for all types of workpiece
material.
Walter AG:
Trigon Cutting Inserts:
Walter recently updated the F2330 milling cutter with Trigon-cutting inserts.
The F2330 used previously in standard milling operations has been improved
to work with difficult machining operations such as circular interpolation,
plunging, and pocketing. Mechanical engineering companies, mold designers
and specialists in the processing of turbine blades will benefit. These inserts
have three cutting edges and a positive basic shape guaranteeing a soft, low-
vibration cut. For fine-tuning the application, three cutting geometries are
available: universal, stable and easy-cutting. The tool bodies, available in
diameters from 0.750" to 4.000", utilize wide flutes in order to avoid chip
packing.
Similar to the Tiger-tec cutting materials, WKP25 and WKP35, Walter is
currently delivering cutting inserts for the F2330 from the new PVD Tiger-tec
types WSP45 and WSM35. These cutting materials have been specifically
developed for the manufacturing of stainless steel or low machinability alloys
such as titanium. These new developments provide an expanded range of
application for high-performance tools, increased cutting speeds and longer
service life in difficult to machine applications.
ATI Stellram:
ATI Stellram specifically designed the 4E Turning Geometry to meet the
demands of machining aerospace-type components, manufactured from high
nickel, high cobalt and titanium-based alloys.
Available in new grade SP0819, 4E inserts utilize an approved aerospace
substrate, and are enhanced with a Nano TiAIN layer PVD coating for
unmatched performance.
ATI Stellram's new 4E Aerospace Turning Geometry provides:
 Longer tool life. The 4E's combination of a new super-hard coating with
micro-grain carbide substrate significantly improves heat and wear
resistance in high temperature alloy machining, enabling longer tool life
and higher productivity.
 Improved component quality. The 4E's new precise reinforced chip
breaker profile with positive cutting action dramatically reduces built-up
edge, leaving a smooth surface finish and greater component dimension
integrity.
 Application versatility. The 4E is designed to machine a wide variety of
materials including stainless steels, high nickel, high cobalt and titanium-
based alloys, helping to reduce inventory, operator error, and cost.
Seco Tools:
Four cutting edged disc mill:
Seco Tools Inc. announced the new SNHQ and LNK-05 insert additions to its
family of disc-milling products, which consists of a wide range of carbide
grades and geometries for a variety of slotting, facing, circular interpolation,
and circlip grooving applications in any material. Both the SNHQ and LNK-05
offer up to four cutting edges per insert and offer wiper flats for applications
requiring a high-quality surface finish. Coupled with its extensive lineup of
cutter bodies, Seco's disc-mill families are among the most complete in the
industry.
The SNHQ line is made up of robust inserts that are free cutting and are less
prone to tool chatter. Like the 335.19 inserts they replace, the SNHQ inserts fit
Seco's 335.19 fixed pocket cutter bodies. The new line offers corner radius
options from 0.008" - 0.236" in right- and left-handed styles.
Like the SNHQs, the LNK-05 inserts are also offered in both left- and right-
hand cutting configurations. The LNK-05 inserts are designed to provide low-
cutting forces to deal with longer overhangs or other unstable machining
conditions. Corner radii range from 0.016" - 0.156". Tests with the LNK inserts
have produced consistent surface finishes finer than Ra<60 µin.
New, slimmer cutter bodies have been added to accommodate machining
narrower slots with the LNK-05 inserts (0.315" - 0.394"). Like its predecessors,
the new cutters are available in both fixed and adjustable pocket configurations.
Valenite LLC:
Air actuated bore tooling:
Valenite LLC has introduced a new MODCO Air Actuated Cylinder Bore
(AACB) tool concept to its line-up of engineered tooling systems. The
developed technology is designed to maximize tool life, enhance part quality,
and eliminate the need for manual adjustments and the error potential associated
with operator-made compensations.
The tool not only eliminates drag marks caused by tool withdrawal, thus
enhancing quality, but also makes true in-process automatic tool point
compensation a practical, economic reality for high-precision applications on
CNC machines. And, because of the resulting improvements in tool life, the
system can actually help reduce the number of dedicated machine tools required
to complete semi-finish and finish boring operations.
The AACB the system is scalable to as small as 8mm diameter, and can be used
for virtually any boring application where precision, tight tolerances,
cylindricity, and repeatability are essential.
At the heart of the Valenite AACB tool are three insert cartridges, set to cut the
semi-finish bore, and a fourth insert cartridge for finishing — a pivoting
cartridge that expands outward to the finish diameter size when actuated by
spindle air.
The new system has demonstrated operational performance that results in bores
with cylindricity measuring under 10 micron, repeatable on diameter to within
1µ while allowing for precision adjustments of the tool point in 5 increments
to compensate for insert wear to help keep maintenance requirements low, and
can be designed to allow use of internal coolant at up to 25 bar pressure. The
system can utilize CBN and PCD inserts for high-speed applications.
BIG Kaiser Precision Tooling Inc:
Ultra-high feed chamfer mill:
BIG Kaiser Precision Tooling Inc. introduces the C-Cutter Mini, an ultra-high-
feed chamfer mill. The C-Cutter Mini's compact design reduces the cutting
diameter to the lowest limit, helping to achieve ultra-high spindle speeds and
feeds.
The C-Cutter Mini delivers multifunctional cutting, including chamfering, back
chamfering and face milling. Its high-speed back chamfering capability reduces
hand de-burring, and face milling is possible with a 45 degree chamfering type
with 0.394" square insert.
The C-Cutter Mini is available in single insert and four-insert designs. The
single insert design utilizes the world's smallest 0.197" square insert with four
cutting edges for smaller 45-degree chamfers and a slightly larger insert for 30-
and 60-degree chamfers.
The four-insert design permits 45-degree chamfering for diameters 0.433"-
1.654". Its "triple effect" design combines four inserts for higher feed rates, a
compact diameter for increased spindle speeds, and a new wear resistant multi
layer PVD coating for increased cutting speeds. In one example, these factors
helped the four-insert C-Cutter Mini achieve 13 times better cutting efficiency
than a competitor's three-insert cutter.
BIG Kaiser Precision Tooling is a leader in high-precision tooling systems and
solutions. With brands including Kaiser, BIG Daishowa, Speroni, Unilock,
Sphinx, and more, BIG Kaiser's line is focused on extreme accuracy and
repeatability.
Emuge Corporation:
Solid carbide thread mills with internal coolant suppy
Emuge Corporation's SHUR-THREAD GFI Series of solid carbide thread mills
are now available with internal coolant supply. By precisely applying coolant
where it is needed, waste is eliminated and chips are efficiently evacuated.
SHUR-THREAD offers high confidence machining, up to 2xD length of cut
and other technologically advanced features. Offering an exceptional balance of
performance benefits and price, the tooling line provides superb value for any
size machine operation or production volume.
Emuge's SHUR-THREAD series combines cutting-edge design elements with
state-of-the-art grinding techniques for enhanced performance, versatility,
reliability and ease-of-use. Featuring premium micro-grain carbide and TiCN-
coated for exceptionally longer tool life, the thread mills are engineered with
multiple spiral flutes to eliminate chatter. Also, a large cutter diameter with high
profile correction ensures true-to-gauge threads, and an extended milling
portion allows for up to a 2xD length-of-cut. To further enhance performance,
an enlarged flute space provides efficient chip evacuation and an end mill-type
shank with clamping flat allows for secure tool holding.
SHUR-THREAD cutters produce threads for applications 1" and under in a
wide range of soft and pre-hardened steels to 58Rc, stainless steels, aluminium,
cast iron, titanium, Inconel, and difficult to machine exotics.
The SHUR-THREAD program consists of 20 tool sizes in two styles, type GFI
and EZFI, and are available from stock. Type EZFI is for thread sizes # 4 - # 6 -
# 8, and type GFI is for thread sizes #10 through 1.0".
RobbJack Corporation:

Feather blend:
Feather Blend is a special patented geometry that reduces the ledging that
occurs in step-down milling. This geometry is a smooth transition from the neck
diameter to the cutting diameter of the end mill that eliminates steps and
mismatching of side walls when multiple axial depths of cut are required.
Feather Blend is helpful for insuring structural integrity and eliminating sharp
corners on machined parts.
RobbJack's patented Mirror Edge geometry causes process dampening of
aluminum material by matching the part frequency to the natural frequency of
the tool. By doing this, more material is removed without increasing chatter.
This geometry is also great for tools with long diameter to length ratios because
the farther a tool sticks out of the spindle, the more inherent flexibility and,
subsequently, the more chatter. Mirror Edge can eliminate this problem. It is
also great for reducing chatter in thin wall aluminum parts.
RobbJack FM Series is the most advanced tooling system available to maximize
high-speed machining center investment.
Kennametal:
Multitype cartridge:
With a steel and aluminum body construction that offers reduced weight,
improved rigidity and vibration-dampening characteristics, the KSCM AluMill
face-milling system from Kennametal is designed to achieve high speeds and
high-productivity results, especially for high-volume aluminum milling
operations.
In particular, automotive applications such as engine blocks and cylinder heads
can benefit from the KSCM AluMill system's design and performance.
KSCM AluMill cutters are available between 2.5" and 12" (63mm and 315mm)
diameters and can accommodate five different cartridge styles for rough and
finish cutting in the same operation or for defined surface-finish requirements.
With easy cartridge insertion and adjustment, maximum runout error is 3mm.
Reduced weight and the ability to be precision-balanced also serve to extend
tool life.
Sumitomo Electric Carbide Inc.

Tangential-style cast iron milling cutter 

A uniquely engineered tangential-style milling cutter from Sumitomo Electric
Carbide Inc. (www.sumicarbide.com) has a finepitch design to produces low
cutting forces for high production and fine surface finishes when cutting gray
and ductile cast irons.
Sumitomo’s new SumiEdge Mill is an 88-degree tangential milling cutter that
allows for the use of all eight cutting edges – first by rotating the LNMX insert
within the pocket, and then by switching the insert from one cutter to the next
(using both left and right-hand cutters). The tools are available in 3- and 6-in.
diameters for both left and right milling cutters.
According to Sumitomo, its new ACK200 and ACK300 grades provide stable
cutting performance and long tool life. The ACK200 grade features a Super FF
coating with an ultrafine TiCN layer for anti-adhesion and wear resistance
during general-purpose machining of gray and ductile cast iron.
The ACK300 grade uses a multilayered Super ZX coating, consisting of
nanometer thick TiAIN and AlCrN layers, coupled with a fine-grained super
tough substrate for fracture resistance.
Kyocera:

MWFN mini
 Low Cutting Force 90° Milling Cutter with Double-sided 6-Edge Insert.
 Small Diameter MFWN Series Milling Cutters
 Uses Cost-Efficient 6-Edge Inserts
 Fracture-resistant inserts and low cutting forces

Steep rake angle minimizes cutting forces and neutral inserts for various uses.
Three insert chipbreakers and four grades available, comprehensive insert
lineup for various machining applications
Additional Fine Pitch, Small Diameter Toolholders Available, Face Mill : ø 50~
ø 125, End Mill : ø 25 - ø 80

Hybrid Cermet for Steel Machining

PV720/PV730
 New stability oriented PV730 added to lineup. New tough micro grain
cermet improves fracture resistance. Good surface finish and wear
resistance.
 Three types of specialized strengthening technology (Hybrid technology)
provides high quality surface finish, excellent fracture resistance and
superior wear resistance.
 General use PV720 : 1st Recommendation for steel machining. Excellent
wear resistance, high-efficiency machining and high quality surface
finish.
 High speed PV710, uncoated type TN610 / TN620 are also available. Full
line-up covers various machining applications.
CVD Coated Cermet for Finishing
CCX
 Newly Developed Unique Cermet Base Material with Thick CVD
Coating
 Greater Productivity with High Speed Finishing
 Superior Wear Resistance to PVD Coated Cermets
 High Speed Machining with CVD Coated Cermet.
 Applicable to a Wide Range of Cutting Conditions from General to High
Speed Machining.
 Maintains Long Tool Life in Soft Steel, General Steel and Cast Iron
Machining

Positive Chipbreaker for Aluminum Finishing

AP Chipbreaker

 Improved Chip Control during Aluminum Finishing Applications

 Combination of Sharp Cutting Edge and DLC Coating Prevents Burrs
 DLC Coated Grade PDL010 is Available

For Super Heat Resistant Alloy

PR005S/PR015S
 Reduce sudden fracture and decrease edge wear.
  Stable machining for super heat resistant alloy.
 SQ chipbreaker: Finishing ~ Medium machining
 SG chipbreaker: Roughing
 SX chipbreaker: High Efficiency Roughing (Single-sided)
 Improved thermal properties helps to reduce sudden fracture and decrease
edge wear
 Improve wear resistance with MEGACOAT HARD coating
 New chipbreaker designs improve machining stability and low cutting
force

Small Internal Machining

PF chipbreaker
 Minimum ø5～ for internal machining.
 Great chip evacuation and low cutting force for small internal machining.
 Combination with EZ Bar PLUS improves operability and enables high
precision machining
 Excellent chip evacuation in various range of machining
 Low cutting force design improves sharpness
 High precision machining with periphery grinding and sharp edge
specification
 Improve adhesion resistance and surface finish due to adoption of a
mirror surface polished insert
 Combination with EZ Bar PLUS improves operability and enables high
precision machining
CVD Coating for Stainless Steel Machining
CA65 Series
Smooth coating surface suppress the welding and built-up edge. Achieve
excellent chip control in combination with stainless steel dedicated chip
breaker.
Sandvick Coromant:
PrimeTurning was introduced by Sandvik Coromant, Fair Lawn, N.J., as a
totally different way of performing turning more efficiently and productively.
In PrimeTurning, the tool enters the component at the chuck and removes
material as it travels toward the end of the component, bringing with it its own
set of interesting programming challenges.

One is the application of small or shallow entering angles and higher lead
angles that create thinner, wider, curved chips that spread the load and heat
away from the nose radius. The result, said the company, is both increased
cutting data and extended tool life due to increased feed rates. In addition,
because cutting is performed in the direction moving away from the shoulder,
there is no danger of chip jamming, which can be a problem in conventional
turning. Entering angles of 25–30º are used to maintain chip control and
tolerances.

Programming is widely recognized as a key to unlocking the potential of

PrimeTurning’s processing capabilities and is available now. For example, CNC
Software Inc., Tolland, Conn., developer of Mastercam CAD/CAM software,
worked with Sandvik in developing programming for PrimeTurning using the
principles of its Dynamic Motion engine to produce toolpaths that can drive the
tool’s motion. Industries likely to benefit the most, according to Sandvik, are
aerospace and automotive manufacturers, where it is necessary to perform
external turning operations in large production runs or where multiple setups
and tool changes are required.
COATINGS:
Recently most of the changes in coatings have been more evolutionary. Changes
to improve performance included using different thicknesses and polishing the
layers. Finding the right coating for a tool is an iterative process. As we have
gone through the evolution of the coating process, we have learned to adapt the
coating to the substrate and cutting parameters.
Current trends in coating technology for hard machining can hardly be
explained on a general basis as the coating applications are becoming more
specialized than ever; for similar machining methods different approaches are
found.

Although the monolayer coating confers the base tool a higher tool life,
generally, when compared to the multi-layered coatings, these coatings
underperform in terms of tool work-life. The multi-layered coatings have a
higher resistance to crack propagation, this coupled with the multiple layers
with various beneficial properties, confers the multi-layered coated tool with
better wear resistance than the monolayered coated tools.
Regarding nanostructured coatings, these are very novel. Recent studies show
that these coatings are even better, in terms of tool life, to the multi-layered
coatings, as a higher number of interfaces between coating layers, confers
excellent mechanical properties to the coated tool. Furthermore, these coatings
have increased crack propagation, due to the high number of layers.
Diamond coatings, however, have proven to be the coatings with the highest
wear resistance, especially due to their high hardness value. There are also
recent studies on the creation of multi-layered diamond coatings, with varying
microstructures, thus achieving a higher tool life.
Coating Design Wear Behaviour Tool Design
Monolayer Coating Abrasive wear; Adhesive Medium tool life
wear; Coating
delamination/destruction
Multilayer Coating Abrasive wear; Adhesive High tool life
wear; Coating
delamination
Nanostructured Abrasive wear; Adhesive Very high tool life
Coating wear
Diamond Coating Abrasive wear; Adhesive Very high tool-life
wear
In the coming parts of this assignment, details about each of the unique and
latest trends will be discussed with further detail with an emphasis on the legion
of work being done on nano structured coatings.
Titanium diboride, a unique coating that resists material transfer from copper or
aluminium. It was used by the casting industry to prevent aluminium from
sticking to moulds, he said, and now it has been adapted for use as a tool
coating.
AlCrN Coating:
The year after introduction of AlTiSiN coating to the market a new coating was
presented by Oerlikon: Balinit Alcrona. This coating is an AlCrN coating
intended for expanding the capabilities of TiAlN coatings especially where high
oxidation resistance is required. The hardness of AlCrN coating is similar to
that of TiAlN, but what makes this coating outstanding is its high oxidation
resistance, up to 1200 °C. That is thanks to the growth of a stable (Al,Cr)2O3
oxide during cutting instead of the TiO2 + Al2O3 oxides which grow in TiAlN
coatings.
nACRo Coating:
The main achievement of AlCrN coatings is limited to a lifetime extension of
hard metal tools under standard cutting conditions and its successful use for
hard metals is usually far from hard-machining conditions. In order to overcome
this limitation Platit developed a new silicon-containing AlCrN coating:
nACRo. This last AlCrSiN-based coating has been successfully applied in
hobbing, drilling and milling when both high temperature resistance and
oxidation resistance of the coating are required.

Diamond Coating:
Diamond Tool Coating LLC, North Tonawanda, N.Y., coats tools with
polycrystalline diamond applied with a CVD process. The company works with
tool manufacturers to develop the right combination of tool and coating to
match such challenging applications as machining composites or graphite. The
diamond coating can withstand the abrasiveness of materials. Not just any tool
can be diamond coated. What tool material we can apply the coating to is
limited. The best substrate is 6 percent cobalt, fine-grained carbide. That will
produce the best adhesion, which is the key to the success of diamond coating.
Bilayer Coating of Poly(3,4-ethylenedioxythiophene)-Halloysite/Chitosan and
Mg2+/Sr2+-Doped HAP on Titanium Alloy. This is done in terms of bio-medical
implants of today. he adhesion and biocompatibility of titanium alloy is
improved by coating with a bilayer, for example, PEDOT-HNT/CS-MHA
composite using the electrochemical deposition method. Corrosion behaviour of
the PEDOT-HNT/CS-MHA bilayer composite coating was investigated in the
PBS medium by polarization studies. The functional groups, phase purity,
surface morphology, and wettability of the PEDOT-HNT/CS-MHA were
characterized by various instrumental techniques like FTIR, XRD, SEM, and
contact angle techniques. In addition, the in vitro bactericidal and cell viability
studies were also carried out to further confirm the biocompatibility of the
protective coating. Hence, the bilayer deposition has shown excellent stability
and biocompatibility and can be used for the potential biomaterials for
orthopedics applications. Electrochemical polymerization of EDOT on the
HNT-modified alkali-treated Ti alloy was done in a three-electrode cell
arrangement using cyclic voltammetry (CV CHI 760C electrochemical
workstation (USA)) in which the alkali-treated Ti alloy and platinum electrodes
were the working electrode and counter electrode, and saturated calomel
electrode (SCE) served as the reference electrode, respectively. The
electrodeposition of ethylenedioxythiophene on the alkali-treated Ti alloy was
achieved in 0.5 M LiClO4 solution containing 0.1 M PEDOT. The applied
potential was scanned between +1.4 and −0.8 V versus SCE for 20 cycles at a
fixed scan rate of 20 mV/s . The electrochemical deposition method was carried
out to deposition a uniform coating of PEDOT on both HNT as well as CS-
MHA-modified Ti alloys. This also shows cyclic voltammetry behavior of
continuous cycling between the preselected potential ranges by placing Ti alloy
substrates in electrolyte solution consisting of a stable dispersion of 0.1 M
LiClO4 containing 0.1 M EDOT and HNT. The electrodeposition was performed
by potential cycling between +1.4 and −0.6 V versus SCE. Inner layers
successively deposited onto the Ti alloy substrates act as an electrical insulator
of undesirable leakage. Before experiment, the coated samples were stabilized
at their OCP. Furthermore, the outside layer of HA composite was coated in the
galvanostatic mode. Successively, CS-HA and CS-MHA composites were
electrodeposited on the coating by chronoamperometry.
 
Coating structure plays an important role on fracture toughness of a coating.
Nano-multilayer or superlattice coatings are found to show more resistance
against microchipping and crack propagation than single layer coatings.
Moreover, these layers assist to transfer of elements to the surface, which
maintains tribo-film formation process in the cutting tool/chip contact region.
The figure below shows different coatings on cutting tool instruments in a
diagrammatic format while the image below shows crack penetration through
various layers in each of the different types of coating.
Nanolayer Hard Coatings:
Nanolayered coatings have excited researchers interest after very high hardness
increment obtained in nanolayer TiN/VN coatings. Main reason of the increase
in hardness and strength of a nanolayer coating was found to be a large number
of interfaces between layers. Maximum hardness was obtained at 5–10 nm
bilayer period thickness. In addition, in this bilayer thickness range, the
columnar structure seen in single layer coatings was found to change in
multilayer superlattice coatings, for example, nanolayer TiAlN coating. In
literature, the difference between multilayer coatings and nanolayer coatings is
not described definitely. Generally, high hardness (super hardness) values
This diagram represents the
obtained in nanolayer coating configurations distinguish them from multilayer
change of coating hardness
coatings. The hardness of nanolayer coatings is not equal towith
average hardness of
layer thickness.
materials constituting the coating, while the hardness of a multilayer coating is
equal to average hardness of materials constituting the coating.

New trend in high-temperature nanostructure control was set when Hitachi®

unveiled endmills coated with TiAlN–TiSiN coatings and soon after, Platit® did
so with AlTiSiN coatings with the nACo™ trademark.

Nanocomposite Hard Coatings

Nanocomposite coatings are a new generation of materials. A nanocomposite
coating composes of at least two phases: a nanocrystalline phase and an
amorphous phase, or two nanocrystalline phases. The nanocomposite materials
show improved properties due to smaller (r10 nm) grain sizes compared to those
of the conventional materials (Z100 nm). The main property of nanocomposite
coatings is an increased hardness. In general more than two times greater
hardness can be obtained in a nanocomposite coating compared to that of its
harder component. The main reasons of the hardness increase are the
dislocation-induced plastic deformation, the nanostructure of materials, and
cohesive forces between atoms of neighbouring grains.
Diamond-Like-Carbon (DLC) coatings:
These coatings have proven to be a great choice for dealing with abrasion
problems. These coatings have incredible high wear resistance. the
characterization of a three-layer CrN/CrCN/DLC is done, and the properties
were assessed. Furthermore, a comparison was made of these coatings against
an uncoated surface and a TiAlSiN coating. It was reported that the three-
layered DLC coating was 58 times more resistant to wear than that of the
uncoated surface. In another study regarding this subject, conducted by Ucun et
al. A comparison of tool performance was made in the micro-milling of Inconel
718, while using DLC coated and uncoated ultra-fine carbide tools. The authors
determined tool performance in terms of tool wear, surface roughness, burr
formation and cutting forces during machining. It was concluded, from the
milling that the DLC coated tool had an overall better performance, exhibiting
less signs of tool wear early on, conferring the workpiece a better surface finish.
Also, due to the low friction of the DLC coating, the cutting forces values for
the coated tool test were lower than that of the uncoated tool. In terms of burr
formation, at low cutting Coatings 2020, 10, 235 7 of 26 lengths, there was no
significant difference between uncoated and coated tool, however, by increased
the length of the cut, the burr formation increases during milling with the
uncoated tool.
A recent study on diamond-coated milling tools presents the fabrication of a
CVD diamond cutting tool to be used in the micro-milling process of oxygen-
free copper . Due to its high hardness, diamond coatings are a promising tool to
be applied in the micro-milling process. Zhao et al. Proposes a novel process to
fabricate these micro-cutting tools by means of laser-induced graphitization and
precision grinding. The authors reported that a loose graphite layer was formed,
which was easily removed. The performance of these tools was reported to be
better than the commercial coated cemented carbide micro-cutting tools that are
used for the machining of oxygen-free copper. Moreover, the resultant surface
finish was better when using these CVD diamond tools and the cutting forces
during the milling process were lower.
Micro Crystalline Diamonds/ Nano Crystalline Diamonds:
In the study performed by Wang et al, the cutting performances of different
diamond coated tools in the high-speed milling of graphite moulds were
analysed. The coatings analysed were microcrystalline diamond (MCD), sub-
microcrystalline diamond (SMCD), nanocrystalline diamond (NCD), and an
MCD/NCD composite. These coatings were deposited via hot filament chemical
vapor deposition (HFCVD), on a WC-Co substrate. It was reported that the
coating with the best adhesive properties to the substrate was MCD, and the
NCD coating showed a lower friction coefficient when machining.
Furthermore, the SMCD coating performance was not satisfactory using these
parameters when compared to the MCD and NCD. However, the MCD/NCD
composite presented good adhesive strength to the WC-Co substrate.
Furthermore, the friction was lower, because the top part of the coating
consisted of NCD, which has a lower surface roughness and finer diamond
particles. This presents a good case for the use of MCD/NCD composite coated
tools in the milling of hot bending graphite molds, and similar materials.
Another study on these types of coatings conducted by Wang et al evaluated
the cutting performance and tribological behaviour of various diamond
coatings: monolayer, bilayer and multilayer coatings, when applied to milling
tools for zirconia ceramics. In that study, the evaluated coatings consisted of
alternating layers of MCD and NCD applied to a cemented tungsten carbide
substrate. These coatings were deposited by HFCVD, as in the study previously
presented. The coatings that were created consisted of: monolayer NCD and
MCD coatings, bilayer MNCD and NMCD coatings and multilayer MNMN-CD
(micro-nano-micro-nano-crystalline diamond) and NMNM-CD (nano-micro-
nano-micro-crystalline diamond) coatings. The authors reported that the
coatings were deposited in a way that the thickness would not influence the
coating performance. As seen in a previous study, NCD coatings presented a
lower surface roughness, which led to lower friction coefficients when
machining. In the study performed by Wang et al. The same phenomenon was
reported. When compared to the monolayer MCD coating, the monolayer NCD
coating exhibited a lower friction coefficient.
The NMNM-CD-coated tools did not perform well in the milling tests, due to
the delamination of the coating. This was due to the low adhesive strength to the
substrate. However, the MNMN-CD-coated tools exhibited high wear resistance
and a high adhesive strength, showing a higher tool life, up to roughly 7.5 times
the tool life performed by the monolayer coated tools.

The Effect of Hard Coatings on Workpiece Surface Finish

The main effects of hard coatings are on surface integrity of the machined
material. The term ‘surface integrity’ is used to describe the attributes of a
machined surface (surface topography and properties of subsurface layer) and
its relationship to functional performance. Performance characteristics that are
most often determined by surface integrity are: fatigue strength, fracture
strength, corrosion rate, and tribological behaviour (such as friction, wear and
lubrication, and dimensional accuracy). A good performance with the machined
component can be obtained under service conditions if its surface integrity is
high. Thereby, it is highly significant to control the surface integrity in
machining processes. Topography, microstructure, texture, surface roughness,
metallurgy, hardness, and residual stresses constitute the surface integrity of a
machined material.

Comparisons between coatings are always being made, in order to achieve the
most optimized process. The coating choice is of great importance, as can be
seen in the study performed by Durmaz et al. In which the authors compare the
performance of TiAlN-, AlCrN- and TiAlSiN- coated carbide tools. In that
study an uncoated tool was used, as well, in order to serve as a comparison. It
was shown that the hardness of the coatings was greater for the AlCrN and
TiAlN films, being followed by the TiAlSiN, the latter exhibiting the best wear
performance of all the coated tools.
However, in terms of critical load support and surface finish quality the TiAlN
coating was the best choice. Studies such as these are important to optimize a
machining process. As seen from the study results, if the focus is tool life or
reduced tool wear, maybe opting for the TiAlSiN coating would be preferred,
but if what is trying to be achieved is a better surface finish, then, the choice
would be a TiAlN coating. Regarding TiAlN coatings, in the study carried out
by Sahoo et al. The influence of TiAlN coating and limiting flute angles of
flutes on the prediction of cutting forces and dynamic stability in micro milling
of P-20 steel were analysed. Sahoo et al. proposed an analytical approach to the
prediction of cutting forces by combining Finite Element Analysis (FEA) and
mechanistic modelling, taking into consideration tool run out, minimum chip
thickness (MCT), elastic recovery, ploughing area and the entry and exit angles
of the flutes. The authors state that the proposed model is a viable option to
predict cutting forces. These studies are extremely useful to the industry, as they
enable the optimization of processes, in this case the micro fabrication
processes, by taking the tool coating effect into account.

Coatings for milling tools in particular:

Regarding coating’s for milling tools, there are still many studies regarding
regular PVD and CVD coatings. Multilayer coatings achieve overall better
results in most applications, when compared to mono-layered and uncoated
tools. By using these coatings, there is a significant improvement on tools’ life
and machining quality. The deposition process is also an important factor, when
choosing a coating for a milling application. PVD and CVD processes achieve
different types of coating. For example, PVD coatings are usually thinner.
These thin coatings provide an excellent choice, when it comes to finishing
operations.
On the other hand, CVD coatings are usually thicker and more oriented for
roughing operations. Also, it is important to note that these deposition methods,
confer the coating with different types of residual stress (tensile and
compressive), that impact the coating’s behaviour when cutting. DLC coatings
are seen in a lot of recent studies and development. In these studies, types of
DLC coatings, such as MCD and NCD, are compared with commercially
obtained PVD and CVD coatings.
Studies have provided a good information of these novel DLC coatings,
showing improved adhesion and increased wear resistance, which contributed to
a higher tool life, showing the high potential of these coatings in various milling
applications, especially in the milling of hard-to-machine materials.
Nanostructured and nanolayered coatings are also a focus of recent research.
These have been tested with very satisfactory results, achieving high values of
tool-life, rivalling the tool-life of more recent DLC coatings. Regarding the
wear mechanisms and patterns of the coated tools. The main types of these wear
patterns for milling tools, is the crack formation/propagation, which is caused
by thermal fatigue effects (high machining temperatures). The study of the wear
mechanisms and wear patterns that the coated tools suffer is still a big focus of
recent research. As this is directly linked with the tool’s-life. Studies on the
wear of coatings, provide a valuable insight on new coating development and
process optimization. Also, the study of the residual stresses that are installed in
the coatings still proves to be very useful, as it provides better understanding of
how these stresses influence the coatings performance, and how it affects
surface finish quality and overall process performance.
Presently, the industry’s focus remains on the optimization of the machining
process, to achieve overall better results, faster and cheaper. Many
developments have been made on the optimization of milling processes using
the Taguchi Method. This method provides the best parameters to achieve a
certain result, such as, a better tool life or a better machined surface quality.
Worth mentioning, is the recent trend to opt for more sustainable machining
methods, such as dry machining and other machining methods that employ
alternative lubrication/cooling methods. Coatings have enabled the use of some
of these more sustainable methods, such as dry machining. However, there are
some recent papers, that study the coupling of these coated tools with
alternative lubrication/cooling methods, such as MQL. Studies show that the use
of these methods, retards the coating’s degradation, enabling the use of the
coated tool for longer. Providing good results in terms of surface finish and
overall process sustainability.
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Company catalogues of the companies mentioned in the assignment were also perused.