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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: 30 June 2026 | Viewed by 17381

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 250 words) can be sent to the Editorial Office for assessment.

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 (18 papers)

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Research

37 pages, 35549 KB  
Article
Surface Microstructural Characteristics of Textured Multicomponent TiN-Based Coated Cemented Carbides
by Xin Tong, Xiaolong Cao, Shucai Yang and Dongqi Yu
Coatings 2026, 16(4), 470; https://doi.org/10.3390/coatings16040470 - 14 Apr 2026
Viewed by 331
Abstract
To address the issues of high cutting temperatures and severe tool wear during titanium alloy machining, this study proposes a hybrid surface modification strategy combining micro-textures and multicomponent titanium nitride (TiN)-based coatings on cemented carbide tools. Using YG8 cemented carbide as the substrate, [...] Read more.
To address the issues of high cutting temperatures and severe tool wear during titanium alloy machining, this study proposes a hybrid surface modification strategy combining micro-textures and multicomponent titanium nitride (TiN)-based coatings on cemented carbide tools. Using YG8 cemented carbide as the substrate, micro-dimple textures were fabricated by fiber laser, and three coatings with different architectures (TiAlSiN, TiSiN/TiAlN, and TiSiN/TiAlSiN/TiAlN) were deposited via multi-arc ion plating technology. Based on a two-factor (texture diameter and texture spacing) and three-level orthogonal experiment, the evolution behaviors of surface morphology, phase composition, and mechanical properties of the textured multicomponent TiN-based coatings were systematically characterized and comparatively analyzed. The results reveal that: compared to the monolithic-structured TiAlSiN coating, the TiSiN/TiAlSiN/TiAlN and TiSiN/TiAlN composite coatings with multilayered composite structures can effectively relieve the residual stress inside the film–substrate system, and significantly suppress the phenomena of coating cracking and localized spallation caused by irregular protrusions of the recast layer at the micro-texture edges. X-ray diffraction (XRD) and crystallite size analyses indicate that the amorphous Si3N4 phase promoted by the Si element in the composite coatings effectively impedes the growth of TiN columnar crystals, achieving significant grain refinement. Mechanical property tests confirm that the existence of multicomponent composite interfaces effectively hinders dislocation movement. Among them, the textured TiSiN/TiAlSiN/TiAlN composite coating exhibits the optimal comprehensive performance; its microhardness, nanohardness, and H/E ratio (characterizing the resistance to plastic deformation) are increased by 17.94%, 8%, and approximately 45%, respectively, compared to those of the textured TiAlSiN coating. This study deeply elucidates the synergistic strengthening and toughening mechanisms between micro-texture parameters and the internal structures of the coatings, providing important theoretical guidance and experimental data support for the surface design of long-lifespan tools oriented towards the high-efficiency machining of titanium alloys. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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20 pages, 25127 KB  
Article
Investigation of Tool Wear and Surface Integrity in Turning γ-TiAl Alloy Under High-Pressure Cooling
by Erliang Liu, Yifan Xu, Baiwei Zhu, Limin Shi and Hailang Zhou
Coatings 2026, 16(4), 428; https://doi.org/10.3390/coatings16040428 - 3 Apr 2026
Viewed by 555
Abstract
To address the issues of high cutting temperature and insufficient heat dissipation during the machining of γ-TiAl alloys, this study systematically investigates the effects of three cooling strategies—dry cutting, flood cooling, and high-pressure cooling—on tool wear and surface integrity. The variations in tool [...] Read more.
To address the issues of high cutting temperature and insufficient heat dissipation during the machining of γ-TiAl alloys, this study systematically investigates the effects of three cooling strategies—dry cutting, flood cooling, and high-pressure cooling—on tool wear and surface integrity. The variations in tool wear, surface morphology, surface roughness, surface defects, microstructure, and microhardness were analyzed in detail. The experimental results indicate that adhesive wear is the dominant wear mechanism under all three cooling conditions. Owing to its superior penetration capability, high-pressure cooling significantly suppresses tool wear, although it may induce groove wear. In terms of surface integrity, high-pressure cooling significantly improves the machined surface quality while reducing surface defects, plastic deformation, and work hardening. Compared with dry cutting, the surface roughness decreases by approximately 9.1%–39.0%, the thickness of the plastically deformed layer is reduced by up to 50.74%, and the degree of work hardening decreases by approximately 11.5%–14.5%. With increasing cutting speed, the surface roughness, plastically deformed layer thickness, and degree of work hardening increase under all three cooling conditions; however, high-pressure cooling still maintains the best overall performance at high cutting speeds. These results indicate that high-pressure cooling effectively suppresses thermo-mechanical coupling in the cutting zone by enhancing coolant penetration and lubrication, thereby providing an efficient approach to reducing tool wear and improving the surface quality of machined γ-TiAl alloys. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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34 pages, 6742 KB  
Article
Multi-Objective Optimization of U-Drill Chip-Groove Structural Parameters Based on GA–BP and NSGA-II Algorithms
by Zhipeng Jiang, Yao Liang, Xiangwei Liu, Xianli Liu, Guohua Zheng and Yuxin Jia
Coatings 2026, 16(3), 346; https://doi.org/10.3390/coatings16030346 - 10 Mar 2026
Cited by 1 | Viewed by 503
Abstract
To address the poor cutting stability and deterioration of hole quality caused by the inherent trade-off between chip evacuation performance and drill-body stiffness in U-drilling, a multi-objective optimization framework was established. The design variables were the core thicknesses L1 and L2 [...] Read more.
To address the poor cutting stability and deterioration of hole quality caused by the inherent trade-off between chip evacuation performance and drill-body stiffness in U-drilling, a multi-objective optimization framework was established. The design variables were the core thicknesses L1 and L2 of the inner and outer chip flutes, the inner and outer offset angles θ1 and θ2, and the inner and outer helix angles β1 and β2. The objectives were to maximize the chip evacuation force and minimize the drill-body strain (which serves as an equivalent indicator of maximizing drill-body stiffness). The chip evacuation force was rapidly evaluated using a mechanistic chip evacuation force model derived from mechanism-based analysis. The drill-body strain was efficiently predicted using a GA–BP neural-network surrogate model. An NSGA-II algorithm combined with the entropy-weighted TOPSIS method was employed to solve the optimization problem, yielding the optimal parameter combination for the U-drill chip-flute geometry. The results show that drilling experiments on 42CrMo under the optimal structural parameter combination reduced the cutting forces in the x, y, and z directions by approximately 11.2%, 13.1%, and 11.8%, respectively. The root-mean-square acceleration in the x and y-directions decreased by about 17.3% and 22.9%, respectively. These improvements effectively enhanced the hole-wall surface roughness and hole diameter accuracy, and further improved chip evacuation smoothness and cutting stability of the U-drill. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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29 pages, 6207 KB  
Article
Research on Load Prediction Method of Aviation Herringbone Gear Dislocation Grinding
by Rongyi Li, Xianbin Li, Zemin Zhao, Shuaiqi Tian, Zhaochi Li, Yuqing Wang, Yichen Tang and Xinhao Tang
Coatings 2026, 16(3), 305; https://doi.org/10.3390/coatings16030305 - 2 Mar 2026
Viewed by 373
Abstract
The gears of helicopter transmission system have strict requirements on machining accuracy, and the accurate prediction of tooth surface grinding force is the key to its manufacturing. The existing model simplifies the micro-contact behavior of the abrasive-workpiece, which limits the accuracy of the [...] Read more.
The gears of helicopter transmission system have strict requirements on machining accuracy, and the accurate prediction of tooth surface grinding force is the key to its manufacturing. The existing model simplifies the micro-contact behavior of the abrasive-workpiece, which limits the accuracy of the grinding load solution. In this paper, the stress state of single abrasive grain at different stages is refined from the micro level, and the grinding force mechanism model of contact area superposition is established. A mechanism-constrained data-driven grinding force prediction algorithm (MCDDP) is proposed. The algorithm integrates the microscopic force mechanism as a physical constraint into the neural network. The experimental results show that the R2 of the model for predicting the normal and tangential grinding forces under multiple working conditions is higher than 0.98, and the average error is reduced by about 17% compared with the traditional model. This study reveals the non-uniform force mechanism of abrasive-workpiece, realizes the integration of mechanism model and data-driven method, and provides engineering theoretical and technical support for grinding force prediction and process parameter optimization of aviation precision gears. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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22 pages, 3218 KB  
Article
Machining Accuracy Prediction of Thin-Walled Components in Milling Based on Multi-Source Dynamic Signals
by Zhipeng Jiang, Xiangwei Liu, Xiaolin An, Xianli Liu, Aisheng Jiang and Guohua Zheng
Coatings 2026, 16(3), 295; https://doi.org/10.3390/coatings16030295 - 27 Feb 2026
Viewed by 475
Abstract
Thin-walled components used in aerospace manufacturing are highly susceptible to machining-induced deformation due to their low structural stiffness and dynamic cutting instability. Although signal-based modeling approaches have been reported for machining process monitoring and performance evaluation, deformation prediction of thin-walled structures requires explicit [...] Read more.
Thin-walled components used in aerospace manufacturing are highly susceptible to machining-induced deformation due to their low structural stiffness and dynamic cutting instability. Although signal-based modeling approaches have been reported for machining process monitoring and performance evaluation, deformation prediction of thin-walled structures requires explicit consideration of structural flexibility. To address this challenge, a deformation error prediction framework integrating multi-source dynamic machining signals with static structural flexibility characteristics is proposed, enabling simultaneous representation of process dynamics and structural response. Kernel principal component analysis (KPCA) is employed to reduce the feature dimensionality, and the extracted low-dimensional features are subsequently used as inputs for a kernel-based support vector regression (KSVR) model to establish the prediction framework. The proposed method was validated through 25 milling experiments conducted on Al7075-T6 thin-walled workpieces, where deformation error was measured at predefined monitoring points under varying process conditions. The results indicate that the proposed model achieves high predictive accuracy for machining-induced deformation, with RMSE values below 13 μm and R2 exceeding 0.89 on both validation and testing datasets, demonstrating strong agreement between predicted and experimental results. In addition, machining vibration amplitude exhibits a consistent correlation with deformation error, confirming that increased energy input and cutting instability significantly exacerbate thin-walled workpiece deformation. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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22 pages, 9837 KB  
Article
Multi-Scale Dual-Attention Feature Network with Bidirectional Temporal Constraints for Tool Wear Monitoring
by Youqiang Xu, Rongyi Li, Xianli Liu, Haotuo Liu, Ying Wang, Xiaohua Liu and Yuqiang Gan
Coatings 2026, 16(3), 291; https://doi.org/10.3390/coatings16030291 - 27 Feb 2026
Cited by 1 | Viewed by 507
Abstract
Accurate tool wear monitoring plays a decisive role in machining efficiency, product quality and reliability in modern manufacturing systems. Existing deep learning methods struggle to balance the high-frequency transient features and low-frequency evolution trends in tool wear signals, often losing key temporal evolution [...] Read more.
Accurate tool wear monitoring plays a decisive role in machining efficiency, product quality and reliability in modern manufacturing systems. Existing deep learning methods struggle to balance the high-frequency transient features and low-frequency evolution trends in tool wear signals, often losing key temporal evolution details when processing long-range degradation data. Therefore, this paper proposes an online prediction method of tool wear value that combines multi-scale convolution and dual-attention temporal features. This method extracts local mutation and trend features in wear signals through multi-scale convolution, captures wear evolution features through bidirectional cyclic network, and adaptively fuses local detail information and global trend through dual attention mechanism SWGC-DA to generate a multi-scale time series feature-driven prediction model. The ablation experiment based on the PHM2010 public data set verifies the effectiveness of the network structure design and demonstrates the model’s superior predictive ability. Experiments on the self-built TiAl alloy milling dataset achieved a stable prediction of R2 up to 99.1%, with MAE and RMSE of 2.29 and 2.47, respectively. The results show that this method significantly improves the accuracy and robustness of wear prediction. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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21 pages, 17711 KB  
Article
Effect of Anodizing and Welding Parameters on Microstructure and Mechanical Properties of Laser-Welded A356 Alloy
by Baiwei Zhu, Hongwei Yuan, Jun Liu, Gong Chen, Tianyun Feng and Erliang Liu
Coatings 2025, 15(12), 1461; https://doi.org/10.3390/coatings15121461 - 10 Dec 2025
Viewed by 770
Abstract
This study investigates the effects of anodizing and welding parameters on the microstructure and mechanical properties of laser-welded die-cast A356 aluminum alloy. The influence of different surface oxidation conditions, namely, no anodized film (NAF), single-sheet anodized film (SSAF), and double-sheet anodized films (DSAF), [...] Read more.
This study investigates the effects of anodizing and welding parameters on the microstructure and mechanical properties of laser-welded die-cast A356 aluminum alloy. The influence of different surface oxidation conditions, namely, no anodized film (NAF), single-sheet anodized film (SSAF), and double-sheet anodized films (DSAF), was assessed. The porosity, elemental distribution, and mechanical behavior was systematically analyzed. The results indicate that anodizing reduces the fusion zone (FZ) size by approximately 5%–15% and increases porosity, primarily due to the thermal-barrier effect, energy consumption during film decomposition, and hydrogen release. Welding speed and defocusing amount have a significant impact on heat input and melt-pool dynamics. Quantitative analysis revealed that lower welding speeds and positive defocusing amount increased the FZ size by 15% and porosity by 2%–5%. In contrast, optimized conditions (welding speed of 4 m/min and 0 mm defocus) enhanced gas evacuation and minimized pore formation. Elemental analysis showed that anodizing promoted Si enrichment and increased oxygen incorporation, with oxygen content rising by 10%–15%, from 0.78 wt% (NAF) to 1.31 wt% (DSAF). Microhardness testing revealed a reduction in heat-affected zone (HAZ) hardness due to thermal softening induced by anodizing, while FZ hardness peaked under optimized welding conditions, reaching a maximum value of 95.66 HV. Tensile testing indicated that anodized films enhance the yield strength (YS) of the fusion zone (FZ) but may reduce ductility. Under optimized welding conditions (4 m/min, 0 mm), the joints exhibited the best overall performance, achieving the YS of 125.28 ± 10.57 MPa, an ultimate tensile strength (UTS) of 193.18 ± 3.66 MPa, and an elongation of 3.46 ± 0.25%. These findings provide valuable insights for optimizing both anodizing and welding parameters to improve the mechanical properties of A356 joints. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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15 pages, 4001 KB  
Article
Model-Based Prediction and Compensation of Structural Loop Cross-Talk-Induced Geometric Errors in Machine Tools
by Feng Wei, Yuchao Fan, Fei Yan, Yubin Huang, Xin Tong and Jian Li
Coatings 2025, 15(11), 1261; https://doi.org/10.3390/coatings15111261 - 1 Nov 2025
Viewed by 821
Abstract
This study compares one traditional prediction model—the conventional single-variable interpolation method—with two newly developed models: an improved multi-variable interpolation model extended from the single-variable formulation, and a more advanced NURBS-based multi-variable interpolation model. All models are integrated into a real-time volumetric error compensation [...] Read more.
This study compares one traditional prediction model—the conventional single-variable interpolation method—with two newly developed models: an improved multi-variable interpolation model extended from the single-variable formulation, and a more advanced NURBS-based multi-variable interpolation model. All models are integrated into a real-time volumetric error compensation framework embedded within a CNC controller, enabling in-kernel correction without external hardware. Accuracy verification is carried out using planar body diagonal measurements obtained from a dense on-machine PDGE data grid across the coupling plane. Quantitatively, the improved multi-variable interpolation model reduces diagonal errors by 71%–74%, while the NURBS-based model achieves 82% (T1) and 84% (T2) reductions, delivering an additional 18%–19% improvement relative to the single-variable baseline. The in-kernel evaluation satisfies 2–4 ms interpolation cycles, confirming real-time feasibility. The proposed framework provides a compact, data-driven solution for predicting and compensating cross-talk-induced PDGEs in precision machine tools. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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18 pages, 9928 KB  
Article
Simulation and Experimental Study of γ-TiAl Alloy Cutting with scCO2-MQL Based on Modified Heat Transfer Coefficient
by Limin Shi, Xuehao Zhao, Lixin Cui, Haonan Chen and Erliang Liu
Coatings 2025, 15(10), 1215; https://doi.org/10.3390/coatings15101215 - 16 Oct 2025
Cited by 1 | Viewed by 1139
Abstract
Current heat transfer coefficient models for scCO2-MQL exhibit critical limitations because they neglect the Mach disk phenomenon and the effects of radial velocity distribution in the scCO2 jets. These theoretical deficiencies result in significant deviations in the thermal predictions, limiting [...] Read more.
Current heat transfer coefficient models for scCO2-MQL exhibit critical limitations because they neglect the Mach disk phenomenon and the effects of radial velocity distribution in the scCO2 jets. These theoretical deficiencies result in significant deviations in the thermal predictions, limiting the application potential of scCO2-MQL technology in γ-TiAl machining applications. This study establishes a modified heat transfer coefficient model incorporating Mach disk and radial velocity distribution correction factors to characterise complex jet flow behaviour. Based on the modified heat transfer coefficient model, comprehensive simulation and experimental investigations were conducted to analyse cutting forces, cutting temperatures, stress distributions, and serrated chip formation during scCO2-MQL machining of γ-TiAl alloys. Results demonstrate that the modified model achieves superior predictive accuracy, with average relative error reductions of 21.8% for cutting force predictions and 37.3% for temperature predictions compared to conventional models. The developed modified heat transfer coefficient model establishes a foundation for the widespread application of scCO2-MQL cutting of γ-TiAl alloys. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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21 pages, 2796 KB  
Article
Study on Ultrasonic Vibration Lapping of 9310 Small-Size Internal Spline After Heat Treatment
by Zemin Zhao, Jinshilong Huang, Qiang Liu, Zhian Zhang and Fangcheng Li
Coatings 2025, 15(9), 1052; https://doi.org/10.3390/coatings15091052 - 8 Sep 2025
Viewed by 981
Abstract
As a key component of aero transmission systems, internal splines suffer from problems of low efficiency and poor precision in traditional lapping processes due to geometric deformation and high hardness after heat treatment. To address this, this study proposes an ultrasonic vibration lapping [...] Read more.
As a key component of aero transmission systems, internal splines suffer from problems of low efficiency and poor precision in traditional lapping processes due to geometric deformation and high hardness after heat treatment. To address this, this study proposes an ultrasonic vibration lapping technology, which combines the synergistic mechanism of high-frequency vibration and free abrasive particles to achieve efficient and precise machining of small-sized hardened internal splines. By establishing an abrasive grain impact trajectory model and a rolling abrasive grain material removal model, the mechanisms of micro-cutting and impact removal of abrasive particles under ultrasonic vibration are revealed. Based on the local resonance theory, a longitudinal ultrasonic vibration system is designed, and its resonant frequency is optimized through finite element modal analysis. An ultrasonic lapping experimental platform is built, and heat-treated 9310 internal spline samples are used for experimental verification. The results show that, compared with traditional manual lapping, ultrasonic vibration lapping significantly improves the tooth profile and tooth lead deviations. After measurement, following ultrasonic vibration lapping, both the total tooth profile deviation and tooth lead deviation of the internal spline meet the Grade 6 accuracy requirements specified in GB/T 3478.1-2008 Cylindrical straight-tooth involute splines (Metric Module, Tooth Side Fit)—Part 1: General. This study confirms that ultrasonic vibration lapping can effectively correct the geometric accuracy of tooth surfaces and suppress thermal damage, and provides an innovative solution for the high-quality repair of aero transmission components. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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19 pages, 6832 KB  
Article
Study on the Optimization of Textured Coating Tool Parameters Under Thermal Assisted Process Conditions
by Xin Tong, Xiyue Wang, Xinyu Li and Baiyi Wang
Coatings 2025, 15(8), 876; https://doi.org/10.3390/coatings15080876 - 25 Jul 2025
Cited by 2 | Viewed by 969
Abstract
As manufacturing demands for challenging-to-machine metallic materials continue to evolve, the performance of cutting tools has emerged as a critical limiting factor. The synergistic application of micro-texture and coating in cutting tools can improve various properties. For the processing of existing micro-texture, because [...] Read more.
As manufacturing demands for challenging-to-machine metallic materials continue to evolve, the performance of cutting tools has emerged as a critical limiting factor. The synergistic application of micro-texture and coating in cutting tools can improve various properties. For the processing of existing micro-texture, because of the fast cooling and heating processing method of laser, there are defects such as remelted layer stacking and micro-cracks on the surface after processing. This study introduces a preheating-assisted technology aimed at optimizing the milling performance of textured coated tools. A milling test platform was established to evaluate the performance of these tools on titanium alloys under thermally assisted conditions. The face-centered cubic response surface methodology, as part of the central composite design (CCD) experimental framework, was employed to investigate the interaction effects of micro-texture preparation parameters and thermal assistance temperature on milling performance. The findings indicate a significant correlation between thermal assistance temperature and tool milling performance, suggesting that an appropriately selected thermal assistance temperature can enhance both the milling efficiency of the tool and the surface quality of the titanium alloy. Utilizing the response surface methodology, a multi-objective optimization of the textured coating tool-preparation process was conducted, resulting in the following optimized parameters: laser power of 45 W, scanning speed of 1576 mm/s, the number of scans was 7, micro-texture spacing of 130 μm, micro-texture diameter of 30 μm, and a heat-assisted temperature of 675.15 K. Finally, the experimental platform of optimization results is built, which proves that the optimization results are accurate and reliable, and provides theoretical basis and technical support for the preparation process of textured coating tools. It is of great significance to realize high-precision and high-quality machining of difficult-to-machine materials such as titanium alloy. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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17 pages, 4636 KB  
Article
Chip Flow Direction Modeling and Chip Morphology Analysis of Ball-End Milling Cutters
by Shiqiang Zhou, Anshan Zhang, Xiaosong Zhang, Maiqi Han and Bowen Liu
Coatings 2025, 15(7), 842; https://doi.org/10.3390/coatings15070842 - 18 Jul 2025
Cited by 1 | Viewed by 1356
Abstract
Ball-end milling cutters are normally used for complex surface machining. During the milling process, the tool posture and cutting parameters of the ball-end milling cutters have a significant impact on chip formations and morphological changes. Based on the Cutter Workpiece Engagement (CWE) model, [...] Read more.
Ball-end milling cutters are normally used for complex surface machining. During the milling process, the tool posture and cutting parameters of the ball-end milling cutters have a significant impact on chip formations and morphological changes. Based on the Cutter Workpiece Engagement (CWE) model, this study establishes a chip flow model for ball-end milling cutters with consideration of the tool posture variation. The machining experiments of Ti-6Al-4V with a 15° inclined plane and different feed directions were carried out. The influence mechanism of time-varying tool posture on chip formation was systematically investigated. The results reveal an interaction between the chip flow direction and the cutting velocity direction. The included angle between the chip flow directions at the maximum and minimum contact points in the CWE area affects the degree of chip curling, with a smaller angle leading to weaker curling. This research provides a theoretical foundation for the optimization of posture parameters of ball-end milling cutters and expounds on the influence of the chip flow angle on chip deformation. Full article
(This article belongs to the Special Issue Cutting Performance of Coated Tools)
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15 pages, 6253 KB  
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
Cited by 1 | Viewed by 888
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 KB  
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
Cited by 1 | Viewed by 1101
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 KB  
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
Cited by 4 | Viewed by 1137
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 KB  
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
Cited by 2 | Viewed by 1251
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 KB  
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
Cited by 1 | Viewed by 1226
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 KB  
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 6 | Viewed by 1680
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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