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Coatings
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Cutting Performance of Coated Tools
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Cutting Performance of Coated Tools

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: 31 August 2025 | Viewed by 2534

Special Issue Editors

Dr. Yue Meng

E-Mail Website
Guest Editor
School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin 150080, China
Interests: evaluation of cutting performance of cutting tools; intelligent monitoring of tool status; the application of deep learning and machine learning in mechanical processing; assessment of machine tool energy consumption
Dr. Xin Tong

E-Mail Website
Guest Editor
School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin 150080, China
Interests: textured cutting tool; cutting performance of cutting tool

Special Issue Information

Dear Colleagues,

Tool wear is a significant problem, and a short service life poses a challenge in cutting processing. With the development of the modern manufacturing industry, titanium alloys, high-temperature alloys, and other difficult-to-machine materials have been widely adopted. However, these materials have characteristics such as low thermal conductivity and small deformation coefficients, which lead to a high cutting force and cutting temperature, as well as serious tool wear problems during cutting. This, in turn, considerably shortens the tool's service life and affects the machining surface quality.

As science and technology progress, green cutting technology is widely utilized in the modern manufacturing industry, thereby increasing the demand in the cutting tools field. Consequently, in order to better adapt to green manufacturing and achieve sustainable development, surface coating technology is applied to tool surface coatings. Hard coating materials with high hardness, high abrasion resistance, and other properties, as well as solid lubricating materials with a low coefficient of friction (soft coatings), are used. These act as a chemical and thermal barrier, preventing direct contact between the tool and the workpiece; reducing the friction and interaction between them; and enhancing the tool's oxidation resistance, anti-adhesion properties, and resistance to abrasive wear, extending the tool life and improving cutting tool performance.

The topics of this Special Issue mainly include, but are not limited to, the following areas:

  • Coatings for cutting tools;
  • Textured cutting tools;
  • Tool wear mechanisms;
  • Tool wear prediction;
  • Tribological behavior;
  • Evaluation of cutting performance of cutting tools.

We look forward to receiving your contributions.

Dr. Yue Meng
Dr. Xin Tong
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • coatings for cutting tools
  • textured cutting tools
  • tool wear prediction
  • tribological behavior
  • cutting performance of cutting tool

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Published Papers (6 papers)

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Research

15 pages, 6253 KiB  
Article
Performance and Mechanism on Sand Mold Ultrasonic Milling
by Bailiang Zhuang, Zhongde Shan, Zhuozhi Zhu, Di Ding and Qi Zhao
Coatings 2025, 15(6), 633; https://doi.org/10.3390/coatings15060633 - 25 May 2025
Abstract
Sand mold milling plays a critical role in digital mold-free casting, but it is prone to damage such as corner collapse, collapse, and cracks during the machining process. To address this issue, ultrasonic vibration was used for sand mold milling in this study. [...] Read more.
Sand mold milling plays a critical role in digital mold-free casting, but it is prone to damage such as corner collapse, collapse, and cracks during the machining process. To address this issue, ultrasonic vibration was used for sand mold milling in this study. By incorporating the solid–liquid transition model for sand mold cutting and considering the deformation characteristics of the shear zone, a prediction model for ultrasonic milling forces in sand mold was developed and experimentally validated. The results demonstrate that increasing the spindle speed and decreasing the feed rate lead to a decrease in cutting force. At high speeds, there is a 15% error between the dynamic milling force model and experimental values. Compared with conventional processing methods, ultrasonic processing reduces cutting force by 19.5% at a frequency of 25.8 kHz and amplitude of 2.97 μm, minimizes defects like sand particle detachment pits on the surface of sand mold, significantly improves surface quality, and enables precise, stable, high-precision, and efficient sand mold processing. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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17 pages, 6284 KiB  
Article
Study on the Energy Storage and Driving Performance of IPMC with Laminated Structure Electrodes
by Jintao Zhao, Yanqi Dong, Zhenjie Zhang, Dongyu Yang, Siyan Zhang and Mingchuan Jia
Coatings 2025, 15(5), 577; https://doi.org/10.3390/coatings15050577 - 13 May 2025
Viewed by 189
Abstract
Ionic polymer–metal composites (IPMC) have the advantages of a large driving mass ratio, low driving voltage, and high current sensitivity, but their low electrode continuity, low energy storage, and unclear driving response mechanisms limit further application and development. In this study, Nafion is [...] Read more.
Ionic polymer–metal composites (IPMC) have the advantages of a large driving mass ratio, low driving voltage, and high current sensitivity, but their low electrode continuity, low energy storage, and unclear driving response mechanisms limit further application and development. In this study, Nafion is used as the base film and metallic silver is used as the electrode material to modify IPMC electrodes. The physical and electrochemical properties of silver-based IPMC with three electrode preparation processes are tested, and the effects of different electrode preparation processes and structures on the energy storage performance and driving performance of IPMC are analyzed. The results show that the electrode coating effect of the Hot Press Chemical Plating method (HPCP) is good and maintains better continuity, and the formed layer electrode can improve the energy storage performance of IPMC, and the enhancement of energy storage performance can improve the driving performance of IPMC. This study enhances the energy storage performance and driving performance of IPMC from the perspective of electrode process and structure and provides a basis for the study of the enhancement of energy storage performance of IPMC by the HPCP electrode preparation process. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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15 pages, 9975 KiB  
Article
Research on the Effect of Micro-Pit Parameters on Tool Wear in Turning GH4169
by Jingshu Hu, Jinrong Liu, Zhiwei Liu and Xinmin Feng
Coatings 2025, 15(5), 543; https://doi.org/10.3390/coatings15050543 - 2 May 2025
Viewed by 213
Abstract
Tools with micro-textures have found wide application in cutting difficult machining materials. The cutting performance of tools is closely related to the arrangement, morphology, and size parameters of micro-textures. In this research, micro-pit tools were used in turning GH4169 in spray cooling. The [...] Read more.
Tools with micro-textures have found wide application in cutting difficult machining materials. The cutting performance of tools is closely related to the arrangement, morphology, and size parameters of micro-textures. In this research, micro-pit tools were used in turning GH4169 in spray cooling. The effect of micro-pit parameters on tool wear was investigated through simulation and cutting experiments. In simulation, a model of cutting GH4169 in spray cooling was built to analyze the wear of micro-pit tools with different parameters, and the optimal combination of micro-pit parameters with excellent anti-wear performance was obtained: when the distance between the micro-pit and tool nose is 60 μm, the diameter of micro-pits is 70 μm, and the pit spacing is 100 μm. In the cutting experiment, micro-pit textures with different parameters were fabricated by femtosecond laser, and cutting experiments were conducted in spray cooling to analyze the wear on the rake face of micro-pit tools. Furthermore, Ansys Fluent was used to simulate the dynamic pressure of oil film on the surface of micro-pits, and the anti-wear mechanism of micro-textured tools was verified. This research provides technical reference for the design and development of micro-textured tools. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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19 pages, 10219 KiB  
Article
Research on the Grinding Force Modeling of Herringbone Gear Tooth Surface Formation Based on the Microscopic Mechanism of Wear Particles
by Rongyi Li, Chenglong Kan, Zemin Zhao, Xianbin Li, Xianli Liu and Zhaochi Li
Coatings 2025, 15(4), 395; https://doi.org/10.3390/coatings15040395 - 27 Mar 2025
Viewed by 334
Abstract
In the process of herringbone gear grinding, excessive grinding force leads to a large increase in grinding specific energy. A large increase in the specific grinding energy can easily lead to an increase in the transient cutting load. It leads to grinding burn, [...] Read more.
In the process of herringbone gear grinding, excessive grinding force leads to a large increase in grinding specific energy. A large increase in the specific grinding energy can easily lead to an increase in the transient cutting load. It leads to grinding burn, tooth surface crack and other undesirable phenomena, which ultimately affect the surface quality and service performance of the workpiece. This paper is based on the contact mechanics of workpiece materials. The number of dynamic effective abrasive particles is considered. Combined with the mechanism of grinding force, the model is developed. Based on the consideration of the wear characteristics of the grinding wheel and the structure parameters of the gear itself, the grinding force model was modified. The accuracy of grinding force model is improved by dividing the effective contact angle of grinding grains into four cases. The experimental results show that the normal grinding force error reaches 10.73% and the tangential grinding force error reaches 10.34%. The model reveals the grinding mechanism, optimizes grinding parameters and improves grinding efficiency. It provides a new way for high-precision machining of aerospace precision herringbone gear. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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19 pages, 19174 KiB  
Article
A Model for Predicting 3D Wear Morphology of Ball-End Milling Tools: Development and Validation
by Rongyi Li, Hengyang He, Caixu Yue, Xianli Liu, Youqiang Xu, Ying Wang and Xiaohua Liu
Coatings 2025, 15(4), 394; https://doi.org/10.3390/coatings15040394 - 27 Mar 2025
Viewed by 347
Abstract
Tool wear prediction is an important research area in the machining industry, which can maximize the utilization of tools. Titanium aluminum alloy is the most commonly used material in the aerospace field, and it is difficult to process. Therefore, the tool wear in [...] Read more.
Tool wear prediction is an important research area in the machining industry, which can maximize the utilization of tools. Titanium aluminum alloy is the most commonly used material in the aerospace field, and it is difficult to process. Therefore, the tool wear in the machining process is serious and non-linear. This results in unpredictable tool wear. In this paper, a three-dimensional (3D) shape prediction method for milling wear of a ball-end milling cutter is proposed. By accurately predicting the tool wear volume, a customized tool dulling standard based on the tool damage percentage is established. Based on the tool material wear rate model and discrete analysis, the force, cutting temperature, relative contact time, and sliding speed of each element in the cutting process of the ball-end mill are solved. Combining the analysis results with the wear rate model, the original model of tool 3D wear morphology (3DWM) prediction was established. Finally, the experiment of cutting titanium aluminum alloy with a carbide tool is carried out to verify the proposed method. The results show that the approximate degree of the wear shape predicted by the model is up to 83.2%. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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20 pages, 13368 KiB  
Article
Effect of Surface-Textured AlSiTiN Coating Parameters on the Performance of Ball-End Milling Cutter in Titanium Alloy Milling
by Shucai Yang, Dongqi Yu and Dawei Wang
Coatings 2024, 14(11), 1458; https://doi.org/10.3390/coatings14111458 - 15 Nov 2024
Cited by 1 | Viewed by 954
Abstract
In the high-speed milling of titanium alloys, the combined application of surface texture and coatings can significantly enhance the performance of cemented carbide tools. Investigating the synergistic effect of surface texture and AlSiTiN coating on tool performance is crucial for advancing the development [...] Read more.
In the high-speed milling of titanium alloys, the combined application of surface texture and coatings can significantly enhance the performance of cemented carbide tools. Investigating the synergistic effect of surface texture and AlSiTiN coating on tool performance is crucial for advancing the development of their integrated preparation process. Therefore, in this study, a cemented carbide ball-end milling cutter is taken as the research object, and a surface-textured AlSiTiN coating is applied to the rake face. The effects of texture and coating parameters on the milling performance of titanium alloys are analyzed, and a regression model is developed to optimize the relevant parameters. The results indicate that the surface texture effectively reduces the actual contact area between the tool and the chip, serves as a storage space for chips, and enhances the wear resistance of the AlSiTiN coating. The coating thickness significantly affects milling force, milling temperature, and surface wear. An increase in coating thickness improves the hardness and integrity of the coating surface, and it also strengthens the adhesion of the texture to the coating. Additionally, precise control of the laser power plays a key role in reducing the milling temperature, while both the number of scans and the scanning speed significantly influence surface wear. Furthermore, maintaining an appropriate distance from the edge is crucial for enhancing the surface roughness of the workpiece. The optimized parameters for surface texture and coating preparation are as follows: coating thickness (h) = 3.0 µm, laser power (p) = 40 W, scanning speed (v) = 1590 µm/min, number of scans (n) = 6, texture diameter (d) = 42 µm, texture spacing (l) = 143 µm, and distance from the edge (l1) = 104 µm. The optimized milling performance of the milling cutter shows a significant improvement. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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