The Life of WC-Co Cutting Tools Treated by Plasma Immersion Ion Implantation

1
The Life of WC-Co Cutting Tools Treated by Plasma
Immersion Ion Implantation

• Authors I.E. Saklakoglu, N. Saklakoglu, V.
  Ceyhun, K.T. Short, G. Collins
• Received 31 August 2006
• Presented by Ben Crummett
• Date 19 October 2007

2
Publication

• Received 10 November 2005
• Revised 8 May 2006
• Accepted 16 May 2006
• Available Online 17 July 2006
• Published June 2007, International Journal of
  Machine Tools Manufacture Vol 47

3
Function of Paper

• In this study, the tool life of plasma immersion
  nitrogen implanted tungsten carbide-cobalt
  cutting inserts has been investigated in
  machining of AISI 4140 steel.

4
Importance of Paper

• Surface strengthening of industrial materials and
  tools is of great interest in industry, and ion
  implantation is one of the more effective
  techniques.
• Plasma immersion ion implantation has emerged as
  a viable alternative to conventional ion
  implantation for specific applications.

5
References

• 1 R.K.Y. Fu, S.C.H. Kwok, P. Chen, P. Yang,
  R.H.C. Ngai, X.B. Tian and P.K. Chu, Surface
  modification of cemented carbide using plasma
  nitriding and metal ion implantation, Surface and
  Coatings Technology 196 (2005) (13), pp.
  150154.
• 2 B.C. Schramm, H. Scheerer, H. Hoche, E.
  Broszeit, E. Abele and C. Berger, Tribological
  properties and dry machining characteristics of
  PVD-coated carbide inserts, Surface Coatings
  Technology 188189 (2004), pp. 623629.
• 3 S.C. Santos, W.F. Sales, F.J. da Silva,
  Sinésio D. Franco and M.B. da Silva, Tribological
  characterisation of PVD coatings for cutting
  tools, Surface Coatings Technology 184 (2004)
  (23), pp. 141148.
• 4 C. Ducros, V. Benevent and F. Sanchette,
  Deposition, characterization and machining
  performance of multilayer PVD coatings on
  cemented carbide cutting tools, Surface Coatings
  Technology 163164 (2003), pp. 681688.
• 5 M. Belmonte, P. Ferro, A.J.S. Fernandes, F.M.
  Costa, J. Sacramento and R.F. Silva,
  Wear-resistant CVD diamond tools for turning of
  sintered hardmetals, Diamond and Related
  Materials 12 (2003) (37), pp. 738743.
• 6 A Anders, Handbook of Plasma Immersion Ion
  Implantation and Deposition, Wiley, New York
  (2000) ISBN 0-471-24698-0.
• 7 G.A. Collins, R. Hutchings, K.T. Short, J.
  Tendys and C.H. Van Der Valk, Development of a
  plasma immersion ion implanter for the surface
  treatment of metal components, Surface and
  Coatings Technology 84 (1996) (13), pp. 537543.
  
• 8 G.A. Collins, K.T. Short and J. Tendys,
  Characterisation of high voltage pulser
  performance in radiofrequency plasmas, Surface
  and Coatings Technology 93 (1997) (23), pp.
  181187.
• 9 G.A. Collins, R. Hutchings, K.T. Short and J.
  Tendys, Ion-assisted surface modification by
  plasma immersion ion implantation, Surface
  Coatings Technology 103104 (1998), pp. 212217.

• 10 M.P. Groover, Fundamentals of Modern
  Manufacturing (second ed), Wiley (2004) ISBN
  0-471-65654-2.
• 11 C. Blawert, B.L. Mordike, G.A. Collins, K.T.
  Short and J. Tendys, Influence of process
  parameters on the nitriding of steels by plasma
  immersion ion implantation, Surface Coatings
  Technology 103104 (1998), pp. 240247.
• 12 C. Blawert, H. Kalvelage, B.L. Mordike, G.A.
  Collins, K.T. Short, J. Jiraskova and O.
  Schneeweiss, Nitrogen and carbon-expanded
  austenite produced by PI3, Surface Coatings
  Technology 136 (2001) (13), pp. 181187.
• 13 R. Sanchez, J.A. Garcia, A. Medrano, M.
  Rico, R. Martinez, R. Rodriguez, C.
  Fernandez-Ramos and A. Fernandez, Successive ion
  implantation of high doses of carbon and nitrogen
  on steels, Surface Coatings Technology 158159
  (2002), pp. 630635.
• 14 R.K.Y. Fu, S.C.H. Kwok, P. Chen, P. Yang,
  R.H.C. Ngai, X.B. Tian and P.K. Chu, Surface
  modification of cemented carbide using plasma
  nitriding and metal ion implantation, Surface
  Coatings Technology 196 (2005), pp. 150154.
• 15 A.D. Anderson, M.H. Loretto and G.
  Dearnaley, Microstructural study of ion-implanted
  WCCo, Materials Science and Engineering 105106
  (1988), pp. 503507.
• 16 J.S. Sun, P. Yan, X.B. Sun, G. Lu, F. Liu,
  W. Ye and J.Q. Yang, Tribological properties of
  nitrogen ion implanted WCCo, Wear 213 (1997),
  pp. 131134.
• 17 J. Rech, Influence of cutting tool coatings
  on the tribological phenomena at the toolchip
  interface in orthogonal dry turning, Surface
  Coatings Technology 200 (2006) (1617), pp.
  51325139.

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Flank Wear

• In this study, the flank wear was measured to
  determine the performance of implanted cutting
  inserts.

• Flank wear occurs on the flank or relief face of
  the tool.
• It results from rubbing between the newly
  generated work surface and the flank face
  adjacent to the cutting edge.
• Flank wear is measured by the width of the wear
  band.

7
Implantation Conditions

• The cutting inserts were ultrasonically cleaned
  before plasma immersion ion implantation
  treatments.
• Nitrogen implantations were performed, applying
  negative high voltage pulses of 30 kV.
• The implantation time was 5 h and the temperature
  was in the range 320520 C. The implantation
  dose was about 21018 ions cm-2.

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Implantation Conditions
9
Tool Life Testing

• The machining trials were carried out on a
  universal lathe under dry conditions.
• Orthogonal cutting experiments were performed on
  AISI 4140 steel.
• The following cutting conditions were used in the
  experiments cutting speed Vc160 m/min, feed
  f0.08 mm/rev, and depth of cut2.5 mm.
• Flank wear was measured by a microscope and
  Vb0.3 mm was selected as the wear criterion.
• The surface roughness of the workpiece was
  measured at several locations along the length of
  the cut using a Mitutoyo model SJ 301 portable
  surface roughness tester.

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Chemical Composition

• Co Cobalt
• W Tungsten
• Ti Titanium
• Nb Niobium
• Ta - Tantalum

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Nitride

• After plasma immersion ion implantation treatment
  the surfaces were covered by orange-skin-like
  formations.

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Nitride

• PIII treatment leads to formation of nitride
  compounds, especially for steels.
• The formation of nitrides in N ion implanted
  WCCo has also been reported by others.
• Consequently X-ray diffraction studies were used
  to investigate whether the orange-skin formations
  were in fact nitride compounds.

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Nitride

• WC and WN X-ray peak positions are shown on the
  treated samples. As is well known, the radius and
  electronic structure of a nitrogen atom are
  similar to those of carbon.
• The implanted nitrogen replaces the carbon in WC
  W(CN), WN and/or WN forms in the subsurface.
• Both WN and WC have a hexagonal close-packed
  lattice structure and similar lattice parameters
  it is very difficult to distinguish their X-ray
  peaks.
• Therefore it is difficult to definitively prove
  WN formations.

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Tool wear as a function of cutting time
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Tool Wear

• It was concluded that nitrogen implantation
  increased the tool life by about 85.
• The best result came from 380 C5 h N2
  implantation conditions at a dose of
  21018 ions cm-2.
• Changing the temperature did not give significant
  changes in tool life.

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Experimental vs. Predicted
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Surface roughness of workpiece as a function of
cutting time.
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Conclusions

• Plasma immersion nitrogen implantation increased
  the tool life by approximately 85.
• Changed PIII temperature did not give significant
  changes in tool life.
• Surface roughness of the workpiece decreased when
  using implanted tools.

20
Practical Industrial Use

• Plasma immersion ion implantation has emerged as
  a viable alternative to conventional ion
  implantation for specific applications, such as
  the implantation of nonplanar components and in
  hybrid treatments such as high energy,
  ion-assisted deposition and energetic ion
  nitriding.

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Technical Advancement?

• Over the last 10 years, Collins and co-workers
  from Australian Nuclear Science and Technology
  Organization have studied the surface treatment
  using a plasma immersion ion implantation system
  of their own design which is described in
  reference 7.

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Industries Most Impacted

• Cemented carbides are used in a variety of
  important industrial components and parts, such
  as cutting tools, milling tools, mechanical face
  seals, drills, punches, submersible pumps, etc.
• Depending on the viability any of the industries
  interested in surface strengthening of carbides
  could be impacted by this.

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Questions?