Experimental vibration analysis of titannium aluminium nitride (TIAIN) coated milling iset effects on AISI 4140 stell surface roughness

The vibration response of material removal process in milling has a significant effect on surface roughness of the product with respect to cutting tool coating. Recent requirements for improving of surface roughness have heightened the need for milling with coated cutting tools. The main objective of this study is to experimentally investigate the role of vibration behavior of cutting tool coated with titanium aluminum nitride (TiAlN) on an AISI 4140 alloy steel work piece surface roughness. The vibration data from work piece were recorded for three milling cutting tools with tool diameters of 10, 12, and 16 mm and for each diameter different coating thicknesses of 0.0, 2.0, 3.0, and 5.0 µ (microns) were used respectively. Vibration signals of work piece during milling process in two directions were collected and a roughness tester was used to measure the surface roughness of work piece. The results showed that vibration due to cutting tool coating thickness has a significant effect on surface roughness of work piece. It has been observed that the maximum average surface roughness was obtained for 16 mm tool diameters with coating thickness of 5.0 µ while the minimum average surface roughness was obtained for 10 mm tool diameters with coating thickness of 3.0 µ Surface roughness can be improved by reduction sources of vibration by using appropriate cutting tool coating thickness. Keywords: AISI 4140, Coated cutting tool, Milling, TiAlN, Surface roughness, Vibration analysis.