Drilling of nodular cast iron with a novel SiO2 coating deposited by sol-gel process in HSS drill

• Published in: International journal of advanced manufacturing technology Vol. 105; no. 11; pp. 4837 - 4849
• Main Authors: Pereira, Natália Fernanda Santos, Rubio, Juan Carlos Campos, dos Santos, Anderson Júnior, Houmard, Manuel, Câmara, Marcelo Araújo, Rodrigues, Alessandro Roger
• Format: Journal Article
• Language: English
• Published: London Springer London 01.12.2019; Springer Nature B.V
• Subjects: CAE) and Design; Cast iron; Computer-Aided Engineering (CAD; Cutting parameters; Cutting tools; Drilling; Drills; Engineering; High speed tool steels; Industrial and Production Engineering; Mechanical Engineering; Media Management; Nodular cast iron; Original Article; Physical vapor deposition; Silicon dioxide; Sol-gel processes; Surface roughness; Thrust; Tool wear; Variance analysis; Drilling; SiO; High-speed steel; Coating; Sol-gel; Cast iron
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-019-04429-z

The present study proposes a novel coating applied on high-speed steel (HSS) drills, thinner and less expensive than the commercial ones. This new coating consists in a silicon dioxide (SiO 2 ) deposited by sol-gel process, and its performance was studied by means of drilling tests in nodular cast iron. For comparison purposes, two other cutting tools were also evaluated: uncoated and TiN-coated by physical vapor deposition process. Four outputs were investigated: thrust force, hole average surface roughness, hole average diameter ( D A ), and tool wear (VB Bmax ). Analysis of variance (ANOVA) was applied to determine the influences of the coatings and drilling parameters on the cutting performances. The results indicated that the SiO 2 coating achieved performances significantly superior to the uncoated tools. They also behaved close to the commercial TiN coating in some aspects. Scanning electron microscopy (SEM) analysis showed predominant flank wear in all the uncoated and coated tools. The “number of holes/maximum flank wear (VB Bmax )” ratios were calculated, indicating a performance 315% better for the SiO 2 -coated tool when compared to the uncoated one. Therefore, the deposition of SiO 2 by sol-gel method is a promising technique to coat rapidly and efficiently cutting tools, including for tools of complex geometries such as drills.