Tool life enhancement through nano-composite coating on the residual stress controlled cutting faces

The high performance machining of steel has reached 150-1500 cm 3 /min of material removal rate at cutting speeds up to 8000 m/min and experiences: chipping, abrasion wear, adhesion and diffusion wear to last for 150-300 m of tool life. On the industrial front the tool life was counted on parameters: surface finish, burr, dimensional tolerance and work hardening. This situation further reduces the tool life to hover around 50-100 m of cutting distance for steel. Therefore a new multiple layer hard coating was developed to achieve: high adhesion strength, high thermal stability, high hardness, low friction coefficient and good compatibility. Field machining tests results suggest that the tool life was extended by 5-10 times than the conventional carbide tools.