Effect of dry micro-blasting on PVD-film properties, cutting edge geometry and tool life in milling

The conduct of micro-blasting on PVD films for improving the cutting performance of coated tools is often encountered in industry. In the present paper, the effect of micro-blasting conditions such as pressure and duration on film mechanical properties, cutting edge geometry and thus on tool life is introduced. The substrate and film stress–strain curves were determined via nanoindentations and evaluation of these results by appropriate finite elements method (FEM) algorithms. Ball cratering tests were carried out at the flank and rake near the cutting edge to detect potential coating thickness change after micro-blasting. Moreover, the effect of micro-blasting conditions on the cutting edge geometry was examined by white light scanning and EDX microanalyses. The cutting performance of coated tools subjected to films' micro-blasting was investigated in milling. FEM supported calculations of the developed temperatures and stresses during material removal contributed for explaining the obtained tool wear results and herewith for optimizing the micro-blasting process.