Tool wear and surface characteristics of TiAlN/AlCrN insert in high-speed turning of bimetal aluminium alloy-grey cast iron engine block

This study investigates the tool wear and surface characteristics of TiAlN/AlCrN-coated inserts during high-speed turning of aluminium alloy and grey cast iron (GCI) in engine blocks. Cutting performance was evaluated at a constant speed of 1,130.4 m/min and a feed rate of 0.18 mm/rev over 300 shots (the number of intermittent cuts). SEM-EDX and roughness analysis revealed abrasion and adhesion as the main wear mechanisms, with a maximum flank wear of 1.14 mm, primarily due to GCI's abrasive nature. Surface roughness measurements for aluminium HD2 and GCI were 7.09 µm and 9.15 µm, respectively. The results highlight the effectiveness of TiAlN/AlCrN coatings but show eventual breakdown under GCI, offering insights for improving tool design in bimetal machining. © 2024 Elsevier B.V.