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techniques used in the industry: chemical vapour deposition (CVD) and physical vapour deposition (PVD) Each of these two technologies in turn includes several different techniques Hard coatings increase abrasive wear resistance as long as they maintain a higher hardness relative to the substrate at the cutting tool temperature It has been argued that resistance to rake face cratering is induced at higher temperatures, although predominantly controlled by chemical wear Super hard coatings are currently under intensive development The development of hard materials used in cutting tools has been driven by the need for increased machining productivity Higher metal removal rates can be achieved by heavier cuts or high cutting speeds Kennametal s new invention of coated PCBN cutting inserts is expected to act as a thermal barrier and thus reduce CBN wear [51] The coating may contain a titanium aluminum Fig 246: A perspective view of a coated cutting tool nitride layer applied by physical vapour with the body having a brazed substrate deposition (PVD) Alternatively, the coating may [51] include a layer of aluminium oxide applied by chemical vapour deposition Figure 246 and Figure 247 show an exemplary cutting tool insert (2) of the invention including a body (4) and a PCBN blank or a substrate (6) brazed to the insert (2) The insert (2) defines a pair of rake surfaces (8) bounded by flank surface (10) The substrate (6) includes two cutting edges (12) and is chamfered as shown generally at reference numeral (14) Alternatively, the substrate may extend only partway along the length of the flank surface to form a tool having a single cutting edge (not shown) In addition, the insert (2) may be fitted Fig 247: A partial cross-sectional view of with an additional blank/substrate (6) at a diametrically the cutting tool [51] opposed corner (not shown) to provide four cutting edges on the tool The method according to the present invention contemplates the use of a polycrystalline cubic boron nitride cutting tool coated with a titanium aluminum nitride layer applied by a PVD technique for hard turning materials such as hardened steel having a hardness of greater than 45 HRC The coating may instead include one or more lower layers of aluminum oxide applied using CVD and an upper layer(s) of titanium carbonitride; titanium oxycarbonitride and/or titanium nitride applied
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using PVD or CVD Finally, it should be mentioned that the important effect of coating is to significantly improve the tool life of the cutting tools The application of hard, wear resistant coating on cutting tools began in the mid-1960s, and today, nearly 70% of the cutting tools are coated Thus, coatings have become an integral part of modern cutting tool materials, and a considerable effort is being expended in the research and development of new coating techniques and materials for manufacturing improved cutting tools The adhesion of the wear resistant coating to the tool surface is the most critical requirement, because the coating cannot be effective unless it is well bonded to the tool
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Table 210 summarizes the compatibility of the cutting tool materials and the workpiece materials Certain tool materials are very limited in their application due to the reactive nature of the material or element in the cutting tool Diamond for instance cannot be used to machine carbon steel although the properties of diamond are very much desirable Table 210 serves as a guide in the selection of a cutting tool for a particular type of workpiece material Table 210 Tool and workpiece material compatibility
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Tool material Suitable High-Speed Steel (18-4-1 and 6-6-4 Moly types) Cast iron cobalt Alloys (Stellite) Cemented Tungsten Carbides (P and K, coated types)
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