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<p>This study presents a comparative evaluation of cutting performance between nanocomposite AlTiSiN-coated and AlTiN-coated carbide tools, both deposited using the scalable pulsed power plasma (S3P) technique, in turning of hardened AISI 4140 steel (51 HRC) under dry environment, which has not been addressed before. To assess the effectiveness of each coating, a series of experiments were conducted by varying the key cutting parameters, namely depth of cut, feed, and cutting speed. The evaluation focused on critical machinability indicators, including crater wear, flank wear, cutting temperature, chip morphology, cutting force, and surface roughness. The findings revealed that the AlTiSiN-coated tool significantly outperformed its AlTiN counterpart, exhibiting a superior surface finish, lower cutting forces, reduced temperatures, improved chip morphology, and minimized tool wear. Importantly, the tool life of AlTiSiN-coated inserts was approximately 26% longer than that of AlTiN-coated inserts under identical cutting conditions. These results demonstrate that AlTiSiN coatings not only enhance machining performance but also offer a more cost-effective solution for hard turning applications in dry environments.</p>

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Performance of AlTiN- and AlTiSiN-Coated Carbide Tools in Dry Turning of Hardened AISI 4140 Steel: A Comparative Investigation

  • 期刊论文

  • 发表日期：

    2025年8月7日

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  • Soumikh Roy,
  • Somyajit Swain,
  • Anshuman Das,
  • Sudhansu Ranjan Das

摘要

This study presents a comparative evaluation of cutting performance between nanocomposite AlTiSiN-coated and AlTiN-coated carbide tools, both deposited using the scalable pulsed power plasma (S3P) technique, in turning of hardened AISI 4140 steel (51 HRC) under dry environment, which has not been addressed before. To assess the effectiveness of each coating, a series of experiments were conducted by varying the key cutting parameters, namely depth of cut, feed, and cutting speed. The evaluation focused on critical machinability indicators, including crater wear, flank wear, cutting temperature, chip morphology, cutting force, and surface roughness. The findings revealed that the AlTiSiN-coated tool significantly outperformed its AlTiN counterpart, exhibiting a superior surface finish, lower cutting forces, reduced temperatures, improved chip morphology, and minimized tool wear. Importantly, the tool life of AlTiSiN-coated inserts was approximately 26% longer than that of AlTiN-coated inserts under identical cutting conditions. These results demonstrate that AlTiSiN coatings not only enhance machining performance but also offer a more cost-effective solution for hard turning applications in dry environments.