Wear analysis of PVD-coated twist drills under MQL

Abstract

Purpose - Deep drilling of hardened steels is a difficult machining operation because of the high wear level of tools. This paper aims to present the main wear mechanisms observed in physical vapor deposition (PVD)-coated twist drills during deep drilling of SAE4144M steel under minimum quantity lubrication, assessed in the production of injection holders. Design/methodology/approach - Two PVD coatings were tested: TiAlN and AlCrN, industrially processed, the last one being a multilayer coating. The workpiece was heat treated for a hardness of 39 HRC to be applied in a diesel engine component. The tests were performed in an industrial environment for a fixed number of holes. Two levels of cutting speed and feed rate were selected for the experiments. In addition, minimum quantity of lubrication (MQL) was compared with conventional lubrication. Scanning electron microscope was used to reveal the wear mechanisms. Findings - Spalling of PVD-coating was revealed for conventional lubrication, while adhesion was observed in MQL conditions. The use of multilayered AlCrN-based coating promoted a significant reduction of adhered material on the twist drill, which is the reason for this selection in industrial operation. Practical implications - Results showed that the MQL regime can be applied for this industrial application. Originality/value - A detailed description of wear mechanisms, which allows a suitable selection of coating and machining variables was found for a very difficult operation, using a more economic process in terms of lubrication.