On the wear of coated carbide inserts in high-speed turning of AISI 1045 steel

This paper presents a study of the wear of coated carbide inserts during high-speed turning of steel. Machining performance measures such as cutting forces and chip-form/chip breakability are analyzed along with a detailed study of progressive wear mechanisms in mono- and multi-layer coated tools. This paper shows that the coating deposition method and the number and thicknesses of coating layers has an important effect in retarding the wear process under conditions of high-speed machining. It was also observed that a direct correlation between eventual wear mechanisms and the initial forces and tool-chip contact lengths is not present. The rate of change of forces provided a good indication of progressive wear. In highspeed turning, crater wear progresses gradually whereas flank wear occurs as a result of rapid increase in crater wear leading to edge failure. The growth of crater wear has clear correlation with the chip-form and chip breakability.