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Comparative study between wear of uncoated and TiAlN-coated carbide tools

in milling of Ti6Al4V

Article  in  Advances in Manufacturing · December 2017

DOI: 10.1007/s40436-016-0166-1

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Adv. Manuf. (2017) 5:83–91
DOI 10.1007/s40436-016-0166-1
Comparative study between wear of uncoated and TiAlN-coated
carbide tools in milling of Ti6Al4V
M. S. Uddin1 • Binh Pham1 • Ahmed Sarhan2 • Animesh Basak3 • Alokesh Pramanik4
Received: 20 July 2016 / Accepted: 19 December 2016 / Published online: 18 February 2017
Ó Shanghai University and Springer-Verlag Berlin Heidelberg 2017
Abstract As is recognized widely, tool wear is a major
problem in the machining of difficult-to-cut titanium
alloys. Therefore, it is of significant interest and impor-
tance to understand and determine quantitatively and
qualitatively tool wear evolution and the underlying wear
mechanisms. The main aim of this paper is to investigate
and analyse wear, wear mechanisms and surface and chip
generation of uncoated and TiAlN-coated carbide tools in a
dry milling of Ti6Al4V alloys. The quantitative flank wear
and roughness were measured and recorded. Optical and
scanning electron microscopy (SEM) observations of the
tool cutting edge, machined surface and chips were con-
ducted. The results show that the TiAlN-coated tool exhi-
bits an approximately 44% longer tool life than the
uncoated tool at a cutting distance of 16 m. A more regular
progressive abrasion between the flank face of the tool and
the workpiece is found to be the underlying wear mecha-
nism. The TiAlN-coated tool generates a smooth machined
surface with 31% lower roughness than the uncoated tool.
As is expected, both tools generate serrated chips. How-
ever, the burnt chips with blue color are noticed for the
uncoated tool as the cutting continues further. The results
are shown to be consistent with observation of other
& M. S. Uddin
Mohammad.Uddin@unisa.edu.au
1
School of Engineering, University of South Australia,
Mawson Lakes, SA 5095, Australia
2
Department of Mechanical Engineering, University of
Malaya, Kuala Lumpur, Malaysia
3
Adelaide Microscopy Unit, University of Adelaide, Adelaide,
SA 5005, Australia
4
Department of Mechanical Engineering, Curtin University of
Technology, Bently, WA 6845, Australia
researchers, and further imply that coated tools with
appropriate combinations of cutting parameters would be
able to increase the tool life in cutting of titanium alloys.
Keywords Tool wear  Titanium alloy  Tungsten carbide
tool  Wear mechanism  High speed machining
1 Introduction
Due to their excellent strength to weight ratio, toughness at
high temperature, and corrosion resistance, titanium alloys
(e.g., Ti6Al4V) have attracted tremendous attention and
been extensively applied as structural components in
aerospace and biomedical industries [1, 2]. Machining as a
mechanical processing technique has been one of fast and
effective operations in manufacturing to provide the final
shape of such components with required geometric accu-
racy and finish. However, the key challenge is the difficulty
to cut or shape titanium alloy materials due to their very
low thermal conductivity [3]. As a result, a high tempera-
ture is generated at the cutting zone, which affects the
cutting tool life (i.e., wear performance) and surface
integrity of the final product. In the past, different types of
cutting tool materials along with combinations of various
cutting parameters and environments have been investi-
gated in cutting of titanium alloys. The cutting tools
studied are made of carbide, high-speed steel (HSS), dia-
mond, while cutting speed and feed rate have been the
dominating parameters influencing the machinability of
titanium alloys [4, 5]. A common consensus in evaluating
the machinability is that the cutting tool wear is the major
factor, affecting the manufacturing productivity as a result
of the underlying interaction and mechanics between the
tool and the workpiece. Among many tools, tungsten
123
84
carbide has been a good choice and widely used cutting tool
in the machining industries due to its high strength and wear
resistance [6]. The carbide tools are made of tungsten carbide
(WC) with cobalt (Co) binders via compacting and sintering,
making the material hard and resilient to heat and wear [7].
The composition of WC-Co is often varied to produce the
tool with required mechanical and tribological properties.
While diamond tools (e.g., polycrystalline diamond (PCD))
offer relatively improved machining performance in terms of
tool life, they are quite expensive and may not be affordable
for mass manufacturing [8, 9]. As a result, tungsten carbide
has shown tremendous potential in high speed cutting of
titanium alloys. Over the years, carbide tools have been
studied in cutting of titanium alloys with a focus on under-
standing of wear and the associated wear mechanisms
[10, 11]. In the cutting of non-ferrous metals, abrasion,
adhesion, attrition and diffusion are shown to be typical wear
mechanisms, of which adhesion and diffusion are often cited
as the dominating effects, particularly, when machining of
titanium. Ghani et al. [12] studied the effects of various high
cutting speeds (120–135 m/min) on carbide tool wear in the
cutting of titanium and reported that higher speed caused
brittle fracture and cracking of the tool edge due to high
temperature induced stress concentration and intermittent
fast thermal loading. They recommended suitable conserva-
tive cutting parameters to minimize tool wear effects. Har-
tung et al. [13] showed that crater wear due to adhesive layers
on the rake face was more dominant at lower cutting speeds
(61–122 m/min), while the tool failed due to plastic defor-
mation at high cutting speeds (122–610 m/min). Adhesive
layers are formed due to the chemical reaction between
titanium and carbide particles via diffusion, which essen-
tially decreases the toughness of the tool edge. Generally,
different tool materials behave differently according to dif-
ferent wear mechanisms. In this regard, hard and wear
resistant coatings, e.g., TiN, TiCN, are applied to the tool
edge to improve the performance. Surprisingly, Ezugwu and
Wang [14] found that the uncoated tool outperformed the
coated tool in cutting of titanium. This finding was contra-
dictory to the findings of other researchers [15]. Wear due to
the elemental diffusion-dissolution through the tool-chip of
carbide tools at high cutting speeds was further emphasized
in Ref. [16]. In a dry cutting of titanium alloy, Gerez et al.
[17] observed that an adhesive layer or built up edge gen-
erated at low cutting speeds often acted as a lubricant, min-
imizing abrasion. However, the layers were momentarily
removed at high cutting speeds, hence accelerating abrasion
at the tool-rake interface.
Therefore, it is clear that insightful understanding of the
wear development and mechanisms is becoming more
important to determine the limit of the tool capability,
enabling one to predict the onset of generation of degraded
surface due to a worn-out/failed cutting edge of the tool.
123
M. S. Uddin et al.
This understanding also allows one to design and develop
better cutting tool materials. The importance of the effect
of tool wear on the machinability is stressed by a wider
community of machining researchers [4, 18].
Keeping this spirit in mind, this paper focuses on further
investigation and analysis of the wear and wear mecha-
nisms of uncoated and TiAlN-coated tungsten carbide tools
in cutting of Ti6Al4V alloys in dry conditions. To follow
up and measure consistent wear development, a series of
side milling operations with the same cutting parameters
were performed. Cutting edge wear, surface roughness and
chips were observed and measured at a certain interval of
cutting distance (often noted as cutting time). The results
are discussed and analyzed with respect to the findings
available in the literature.
2 Experimental details
2.1 Workpieces
The machining was conducted on the workpieces made of
Ti6Al4V alloys. The chemical compositions and mechan-
ical properties of the material are presented in Tables 1 and
2. The as-received material block was cut into a size of 100
mm 9 100 mm 9 80 mm (L 9 W 9 H). The top and
bottom surfaces of the specimen were further rough
machined with a very shallow cut to clean and even out the
surfaces. This process used a 60 mm diameter solid carbide
indexed cutter running with a feed rate of 500 mm/min and
a spindle speed of 1 200 r/min.
2.2 Cutting tools
As cutters, two types of tungsten carbide end mills are
used. One is uncoated (Hanita D014 supplied by Wahida
Inc., Japan) and the other is coated with TiAlN via physical
vapor deposition (PVD) method (KCPM 15 is supplied by
Kennametal Inc., USA). The geometric dimension of both
cutters is as follows: diameter D1 = 12 mm, number of
flutes = 4, total length L = 83 mm, working length l = 26
mm, helix angle = 30°, axial rake angle = 6° and secondary
clearance angle = 15°. Figure 1 shows photographs of both
the coated and uncoated carbide cutters used. The physical
and mechanical properties of the tungsten carbide and
TiAlN-coated tools are summarized in Tables 3 and 4.
Before actual cutting tests, the edges of the cutters are
observed to be sharp and clean without any dirt.
2.3 Experimental
Using a CNC 4-axis vertical milling machine (Bridgeport’s
VMC 480PS, USA), a series of side milling operations
Comparative study between wear of uncoated and TiAlN-coated carbide tools in milling of Ti6Al4V 85

Table 1 Chemical composition of Ti6Al4V alloy

Element w(Ti)/% w(Al)/% w(V)/% w(Fe)/% w(C)/% w(N)/% w(H)/% w(O)/%

Value Balance 6.15 4.40 0.09 0.05 0.01 0.005 –

Table 2 Mechanical properties of Ti6Al4V alloy at room temperature of 25 °C

Hardness (HRC) Elastic modulus/GPa Yield strength/MPa Tensile strength/MPa Density/(kgm-3)

36 114 830 993 4 540

were performed on the workpiece. Figure 2 depicts
experimental setup and illustration of cutting paths con-
sidered during tests. As titanium alloy is hard and difficult
Fig. 1 Tungsten carbide end mills used in the tests
to machine, higher cutting speed and feed rate are con-
sidered. The cutting parameters used are as follows: cutting
speed v = 80 m/min, feed rate f = 0.2 mm/r, width of cut d =
1 mm. During machining, the cutter was engaged with the
workpiece at 10 mm depth along the tool axis direction,
i.e., axial depth was 10 mm (see Fig. 2). The cutting con-
ditions were kept constant for machining with both types of
cutters. In order to understand the tool wear performance,
the cutter was observed at a certain interval of the cutting
length. To do this, the cutter was taken out of the spindle
head and the tool holder, and examined under microscopes.
A cutting length interval of 1 m was considered for the
uncoated cutter while a cutting length of 2 m was used for
the coated cutter. As it is expected that the coated one will
experience less wear as the cutting progresses. The flank
wear and wear mechanism were observed, measured and
recorded by an optical microscope equipped with high
resolution camera (Wild Heedbrugg’s Wild M20, V =
1.4X, Switzerland). Cutting chips were collected to
understand and observe the effect of tool wear on the
change of temperature in cutting zone. The topology of the
tool, machined surface and chips were further observed by
scanning electron microscopy (SEM) (FEI’s Quanta 450
equipped with EDX capability, Netherlands). The process
was repeated until the cutters reached closer to failure (i.e.,
average VB = 0.3 mm) according to the failure criterion
[19]. Note that the notation VB was generally defined as the
height of the flank wear region of the cutting tool. All the

Table 3 Physical and mechanical properties of tungsten carbide end mill

Hardness (HV10) at 25 °C Density/(gm-3) Elastic modulus/GPa Thermal expansion rate/K-1 Particle size/lm

1 470 14.5 580 GPa 5.5 9 10-6 0.8

Table 4 Physical properties of the TiAlN coating

Type Material Thickness/lm Melting point/°C Hardness (HV10) at 25 °C

PVD TiAlN 4 3 070 2 300

123
86
Fig. 2 Experimental setup and cutting paths used in milling tests
machining was performed in dry environment without using
any external coolant or lubricant. In addition to wear, the
arithmetic average roughness (Ra) of the machined surface
was measured by a roughness tester (Mitutoyo’s Surftest SJ-
210, cut-off length 2.5 mm, contact mode, stylus tip radius 5
lm, JIS-B0601 standard, Japan). The roughness values on
five locations of the surface were measured and their
average was considered. The same experimental procedure
was followed for the cutting tests with both uncoated and
TiAlN-coated tungsten carbide cutters.
3 Results and discussions
3.1 Tool wear
The main focus is to investigate the tool wear and wear
mechanism associated with machining titanium alloy. In
general, the cutting tests continue until the tool reaches a
standard failure criterion, i.e., average flank wear is 0.3 mm
for carbide tool. Figure 3 depicts a comparison of the tool
Fig. 3 Comparison of the uncoated and TiAlN-coated tool wear
progress as a function of cutting length
123
M. S. Uddin et al.
flank wear progression with respect to the cutting length for
the uncoated and coated tools. It can be seen from Fig. 3
that, as the cutting length increases, TiAlN-coated carbide
tool exhibits a lower wear than the uncoated tool. For
instance, after a cutting of 10 m, the coated tool reaches a
wear value of 0.143 6 mm, which is about 32% smaller
than that of the uncoated tool wear (0.21 mm). The coated
tool can cut up to 22 m in length with wear progression of
about 0.23 mm, while the uncoated tool reaches wear of
about 0.321 mm (i.e., failure criterion) at a shorter cutting
distance of 16 m. Overall, the coated tool, generally after a
cutting of 16 m, shows an enhancement of tool life by
about 44% over that of its counterpart. Further, a cutting
tool generally follows a three region wear characteristics:
initial wear zone with relatively high wear, steady state
wear region and accelerated wear region leading to failure
[20]. As shown in Fig. 3, both the uncoated and coated
tools show approximately three wear zones as indicated by
the A-B-C and A0 -B0 -C0 areas, respectively. The initial wear
rate of the uncoated tool is larger than that of the coated
tool as the slope of the curve in A zone is shown to be
relatively high. Further, the steady state wear region for the
uncoated tool starts after about a cutting distance of 3.5 m,
while for the coated tool it starts after cutting of 2 m. The
stability of the region is longer than that of the uncoated
one. This comparison indicates that the TiAlN-coated tool
exhibits a better tool life or wear resistance and can be
safely used for a greater cutting length in machining of
titanium alloys. Moreover, the findings are consistent with
those of other researchers [21, 22].
3.2 Wear mechanisms
In order to evaluate the machining performance of the
cutting tools, an understanding of the underlying wear
mechanisms is essential. The wear and wear mechanism
Comparative study between wear of uncoated and TiAlN-coated carbide tools in milling of Ti6Al4V
Fig. 4 Wear in uncoated carbide tool at a cutting length of 16 m a abrasion on flank land b chipping/plastic deformation on cutting edge c BUEs
vary with the combination and interaction of the cutting
tool and the workpiece, in addition to the cutting envi-
ronment. As titanium is hard material, the wear mecha-
nisms that influence the failure of carbide tools may be
different from those when machining other materials. As a
representative example, Fig. 4a shows SEM images of the
flank wear land of the uncoated tool after a cutting of 16 m.
A large abrasive wear region along the cutting edge is
observed on the uncoated tool. As the wear increases, the
onset of tool failure is initiated by small edge chipping and/
or plastic deformation as seen in Fig. 4b. This chipping is
due to the increased friction because of wear causing
thermal stress at the edge. Built up edges (BUEs) due to
adhesion between the tool and the workpiece materials are
noticed on the cutting edge and flank region (see Fig. 4c),
which are expected to potentially further accelerate abra-
sion and friction between the tool and workpiece, and
result in increased wear.
For the same cutting distance, the cutting edge of the
coated tool appears to be very smooth with very small or
87
minor wear marks on the flank land, as shown in Fig. 5a.
The observed gradual flank wear can be due to the
increased wear resistance of the TiAlN coating during
continuous abrasion of the tool with the workpiece.
Similar progressive wear on the flank region for the
coated tool in cutting of titanium was reported by Dhar
et al. [21]. No significant chipping and fracture on the
cutting edge were observed. But, similar to uncoated one,
sticky BUEs are noticed on the cutting edge. However, it
is notable that the coating on the cutting edge appears to
come off due to the continuous abrasion between the
workpiece (including BUE) and the tool (see Fig. 5b). As
reported by König et al. [23], accelerated adhesion took
place after the coating had been removed due to pro-
longed cutting. In such a case, the adhered material was
hit and squashed by the tool in the event of re-entry into
the workpiece, resulting in chipping and eventually
leading to the breakage of carbide at the cutting edge. The
adhering metal was often noticed on the flank face rather
than on the rake face. This finding clearly supports our
123
88
Fig. 5 Wear in TiAlN coated carbide tool at a cutting length of 16 m a flank wear with BUEs b removal of coating due to abrasion
observation and analysis on the wear and wear mecha-
nism of the uncoated and coated carbide tools.
In this study, we employed a single set of relatively
conservative-medium cutting conditions (speed of 80
m/min, feed rate of 0.1 mm/r), and no severity of the tool
damage or failure was noticed for the coated tool even after
a cutting of 22 m. However, at a cutting speed of more than
100 m/min, cutting edge cracking and brittle fracture due to
high stress concentration because of high temperature are
often regarded as the major reasons for tool failure [15].
This phenomenon has been reiterated and observed by
many researchers [10, 11, 24]. In particular, Ghani et al.
[12] recently reported that cutting titanium at a speed of
120–135 m/min was likely to induce high temperature at
the cutting edge, which weakened the micro-bonding
between the carbide particles and their binders, thus
resulting in early brittle fracture at the nose of the tool.
As seen in Fig. 5b, the TiAlN coating is expected to be
diffused and removed from the cutting edge. Thus, the part
of the tool which is engaged with the workpiece becomes
uncoated causing the tungsten carbide to be exposed at the
cutting zone. This suggestion can be further supported by
the presence of fairly large amount of Ti on the tool edge
detected by EDX and illustrated in Fig. 6. Diffusion of the
coating materials into the workpiece/chips resulting in tool
failure has been reported by researchers. In an extensive
study by Odelros [25], EDX analysis revealed a high
content of Ti in the particles that adhered to the cutting
tool, indicating that the detected Ti content was due to the
underlying chemical reaction between the coating material
and titanium alloy. It is notable that these adhered layers of
materials (often termed as BUE) cause furthur abrasion
between the tool and cutting chips/workpiece, hence
resulting in accelerated wear on the flank face of the tool.
123
M. S. Uddin et al.
Similar wear mechanisms with an extensive EDX analysis
of chemical compositions and their diffusions of BUE
materials in the cutting of titanium alloys were reported in
Ref. [26]. Note that, in this study, the crater wear region is
not of interest as at low cutting speed, flank wear is often
regarded as the dominant indicator of tool wear perfor-
mance [10].
In a dry cutting, reduction of cutting induced tempera-
ture is essential to sustain tool life. While the use of cutting
lubricants and coolants is found for certain extent, the
design of heat and wear resistant tool material with low
friction needs to be developed to minimize the cutting
temperature. In addition, proper choice of cutting param-
eters including cutting speed and feed rate, which are
shown to be the most dominating factors in influencing the
tool failure, needs to be sought in order to improve the
machinability of titanium alloys.
3.3 Surface roughness and cutting chips
The surface roughness and cutting chips were investigated
as a measure of the tool performance. Figure 7 illustrates
roughness average of machined surface for uncoated and
coated tools with respect to the cutting length. It can be
seen that at a cutting distance of up to 2 m, the uncoated
and coated tools exhibit almost the same roughness (Ra =
1.88 lm). After this, the uncoated tool shows a drastic
increase in roughness as compared to the coated tool as the
cutting length increases. For instance, at a cutting length of
16 m, the roughness for the coated tool is about 31% lower
than that for the uncoated tool. It is to be pointed that the
larger roughness with the uncoated tool is due to severe
flank wear on the cutting edge, as observed in Fig. 4. Wear
further causes large cutting forces, hence accelerating
Comparative study between wear of uncoated and TiAlN-coated carbide tools in milling of Ti6Al4V
Fig. 6 EDX analysis of the elements on the coated tool surface
Fig. 7 Comparison of surface roughness between uncoated and
TiAlN-coated tools
development of micro fracture and chipping at the cutting
edge, and as a result of this, an uneven machined surface is
generated [27]. Figure 8 shows SEM images of machined
Fig. 8 SEM photos of machined surface topology at a cutting distance of 16 m for a uncoated tool and b TiAlN coated tool
89
surface topology for the uncoated and coated tools at a
cutting distance of 16 m. The uncoated tool reveals some
unexpected dents and dirt on the surface, causing a larger
roughness (Ra = 2.89 lm). On the other hand, the surface
machined and the coated tool appears to be relatively
smooth with fine cutting marks with a roughness of Ra =
2.21 lm. The results clearly indicate that, in addition to
prolonged tool life, the TiAlN-coated tool is able to gen-
erate improved surface quality.
Further, cutting chips or swarf generated at the cutting
zone were collected and observed by optical microscopy.
Figure 9 shows the chips generated by uncoated and
TiAlN-coated tools at a cutting distance of 16 m. More
discontinuous and fracture chips are noticed for the
uncoated tool (see Fig. 9a). Further, burnt chips with blue
color are observed, which could be due to the heat gener-
ated at the cutting zone of the blunted tool due to wear. On
the other hand, the coated tool generates fairly continuous
123
90 M. S. Uddin et al.

Fig. 9 Optical microscopic photos of chips formed by a uncoated tool, b TiAlN coated tool at a cutting length of 16 m and c magnified SEM
photo of the chips

and unbroken chips (see Fig. 9b). Interestingly, chips 4 Conclusions

generated by both tools appear to be of the saw tooth or
serrated type, as shown in Fig. 9c. Mechanisms and This paper has focused on an investigation and comparison
modelling of serrated chips generated during cutting of of the wear progression and wear mechanism of uncoated
titanium alloys were widely reported and confirmed by and TiAlN coated tungsten carbide tools in high speed
many research works in Refs. [28–31]. It is shown that cutting of Ti6Al4V alloy. The followings are the key
the small initial chip thickness and large rake angle affect conclusions drawn from this study.
the generation and geometry of regular serrated chips
(i) The TiAlN coated tool exhibits improved tool life
[32]. While the initial thickness is related to the feed rate
with approximately 44% lower flank wear than the
to be chosen, the actual chip thickness during the cutting
uncoated tool at a cutting distance of 16 m.
can be affected by the cutting edge of the associated tool.
(ii) A more regular progressive abrasion between the
Therefore, it is possible that the severe tool wear at the
flank face of the tool and workpiece is found. The
cutting edge may influence the geometry of the serrated
underlying wear mechanism and small edge
chips. Hence, in order to minimize the serrated chipping,
chipping and/or plastic deformation for prolonged
the tool wear must be regulated to an acceptable level
cutting are noticed for the uncoated tool.
without sacrificing machining productivity. With this aim,
(iii) Diffusion as a form of BUEs due to the chemical
one possible solution is to develop a predictive model of
reaction between the coating and the workpiece
the energy efficient machining of titanium alloys by
materials at high cutting temperature is shown to
controlling inherent cutting temperature and vibration
cause the removal of coating from the tool, and
generated [33], which will allow the optimum machining
weakez the cutting edge, which may result in
conditions including cutting parameters to be chosen to
further acceleration of potential failures.
enhance the tool life.

123
Comparative study between wear of uncoated and TiAlN-coated carbide tools in milling of Ti6Al4V
(iv) The TiAlN coated tool generates smooth
machined surface with 31% lower roughness over
the uncoated tool. As is expected, both tools
generate the serrated chips. However, burnt chips
with blue colour are noticed for the uncoated tool
as the cutting continues further.
Acknowledgements The authors like to thank Adelaide Microscopy
Unit of University of Adelaide for their support in using SEM and
EDX for observation of cutting tools and machined surfaces.
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