Despite having advantages like high productivity and green manufacturing, the application of high speed dry machining (HSDM) is limited because it is associated with high cutting zone temperature that expedites the tool wear. Therefore, improved coating properties are needed in HSDM. The high power impulse magnetron sputtering (HiPIMS) is the latest addition in PVD, which seems to be a promising coating technology for enhancing the performance of the coated tools. In the present study, the HiPIMS coated TiAlN tool was employed in HSDM along with a direct current magnetron sputtered (DCMS) TiAlN coated tool, to examine the prevailing ambiguity regarding their relative performance. To accomplish the objective, plain carbon steel was turned at 600 m/min for 20 s in dry mode with TiAlN coated tool deposited by HiPIMS and DCMS. Thereafter, flank wear and cutting force were investigated to evaluate the machining performance of the tools. Before machining, the physical, mechanical, and chemical properties of the coatings were assessed to correlate them with machining performance. HiPIMS coated tools showed denser coating morphology, higher hardness, and more compressive residual stress than DCMS. The surface roughness of the coatings influenced the flank wear resistance significantly, followed by the coating's hardness. A combined factor of roughness and hardness was established to correlate with flank wear resistance, which showed a good agreement with the experimental data.

尽管具有诸如高生产率和绿色制造的优点，但是高速干式加工（HSDM）的应用受到限制，因为它与较高的切削区域温度相关联，从而加快了工具的磨损。因此，在HSDM中需要改善的涂层性能。高功率脉冲磁控溅射（HiPIMS）是PVD中的最新产品，它似乎是一种有前途的涂层技术，可提高涂层工具的性能。在本研究中，将HiPIMS涂层TiAlN工具与直流磁控溅射（DCMS）TiAlN涂层工具一起用于HSDM中，以检查其相对性能方面普遍存在的歧义。为了实现该目标，使用由HiPIMS和DCMS沉积的TiAlN涂层工具以干燥模式将普通碳素钢以600 m / min的转速旋转20 s。之后，研究了侧面磨损和切削力，以评估刀具的加工性能。在加工之前，先评估涂层的物理，机械和化学性质，以将其与加工性能相关联。与DCMS相比，HiPIMS涂层工具显示出更紧密的涂层形态，更高的硬度和更大的压缩残余应力。涂层的表面粗糙度显着影响后刀面的耐磨性，其次是涂层的硬度。建立了粗糙度和硬度的综合因素，以与后刀面耐磨性相关，这与实验数据显示出良好的一致性。评估涂层的化学性能，以使其与加工性能相关联。与DCMS相比，HiPIMS涂层工具显示出更紧密的涂层形态，更高的硬度和更大的压缩残余应力。涂层的表面粗糙度显着影响后刀面的耐磨性，其次是涂层的硬度。建立了粗糙度和硬度的综合因素，以与后刀面耐磨性相关，这与实验数据显示出良好的一致性。评估涂层的化学性能，以使其与加工性能相关联。与DCMS相比，HiPIMS涂层工具显示出更紧密的涂层形态，更高的硬度和更大的压缩残余应力。涂层的表面粗糙度显着影响后刀面的耐磨性，其次是涂层的硬度。建立了粗糙度和硬度的综合因素，以与后刀面耐磨性相关，这与实验数据显示出良好的一致性。