Finite Element Analysis for Orthogonal Cuttings of Hardened AISI 52100 by Advanced cBN-TiN Composite Coated Tools of Two Depositing cBN Particle Sizes

A finite element model is developed to predict the temperature distribution and stress distribution in orthogonal machining of hardened AISI 52100 steel (62HRC) from using advanced cBN-TiN composited coating cutting tools. The advanced cBN-TiN composited coating tool is made of innovative two-stage composite coating methods: ESC (electrostatic spray coating) and CVI (chemical vapor infiltration). For a cBN-TiN composite coating on WC substrate cutting tool used in hard turning process, the ESC of nano-to-micron cBN particles forms a layer over WC-Co and TiN-TiC cermet tool inserts. CVI introduces TiN as binding material through the porous matrix to form a very dense coating. The finite element model is developed for hard turning simulations of composite coating cutting tools with different particulate particle size distributions. In this paper, two different size distributions of depositing cBN particles are investigated: cBN particle sizes of 0.5 and 2μm. Since solid Poly-crystalline Cubic Boron Nitride (PCBN) tool is the dominant cutting tool used for hard turning applications, a comparative study of this advanced composited coating tools to solid PCBN can suggest a possible comparable alternative cutting tool for hard turning applications. Solid PCBN tool provides a lower maximum temperature than cBN-TiN coated tools. A better surface finish on cutting tool surface also has a significant role in lower the maximum temperature in this study.