Study of tribofilms generation at different cutting speeds in dry machining hardened AISI T1 and AISI D2 steel

Abstract

Hard dry machining of AISI T1 and AISI D2 steels at comparable hardness (around 59 HRC) were performed at 50 m/min, 80 m/min and 100 m/min cutting speeds separately with uncoated alumina ceramic tool inserts (Al₂O₃ + TiC), in order to study the effect of cutting conditions on the generation of tribofilms. Comprehensive assessment of uncoated ceramic inserts in machining of T1 and D2 at different cutting speeds was made by optical microscope, scanning electron microscope and X-ray photoelectron spectroscopy. It was shown that higher cutting speeds increased the formation of thermal protective and/or lubricating tribofilms. In machining D2 steel, more intensive formation of Cr-O tribo-oxides brought a lower wear rate; while in cutting T1 steel, a higher amount of W-O tribofilms generation provided better lubrication. At higher cutting speeds, wear/friction behaviour changes were attributed to differences in two factors: first, from a traditional micro-scale standpoint, the distribution of carbide within steels and the accumulation of thermal and mechanical damages during different cutting conditions; second, from a new nano-scale viewpoint, the generation of protective/lubricating tribofilms due to change of machining conditions.