Advances in Science and Technology

Research Journal
Advances in Science and Technology Research Journal 2023, 17(6), 367–377 Received: 2023.09.11
https://doi.org/10.12913/22998624/174907 Accepted: 2023.11.07
ISSN 2299-8624, License CC-BY 4.0 Published: 2023.11.23

Empirical Study on the Effect of Tungsten Carbide Grain Size

on Wear Resistance, Cutting Temperature, Cutting Forces
and Surface Finish in the Milling Process of 316L Stainless Steel

Emilia Franczyk1*, Marcin Małek1

1
Cracow University of Technology, Mechanical Faculty, al. Jana Pawła II 37, 31-864, Krakow, Poland
* Corresponding author’s e-mail: emilia.franczyk@pk.edu.pl

ABSTRACT
Cutting tools made of the WC-Co sintered carbides are now very popular and are widely used in machining of
materials. However, there are numerous problems in this area which require more research and need to be studied
further. This paper presents the results of an experimental study aimed at discovering the impact of the microstruc-
ture, particularly of the tool substrate grain size, on the quality of the machined surface, cutting forces and tempera-
ture in the cutting zone, as well as the tool life. In addition, the impact of the feed was considered. The machining
process involved side milling of a cuboidal block made of the AISI 316L steel which, due to its specific properties,
is widely used in many industries. The tools used in the tests had different WC phase grain size: 0.18, 0.28 and
0.31 μm, respectively, and moreover the middle specimen had also a non-homogeneous structure and an increased
content of the Co matrix. The tests proved a significant impact of the tool microstructure on the tool life and the
roughness parameters Ra and Rz of the machined surface. The impact of the studied factors on the forces and the
temperature in the cutting zone was not as strong, because it did not exceed 20%. The value and the novel character
of the paper results from the fact that it concerns a specific case: side milling of the 316L steel with the use of the
WC-Co sintered carbide tools, and consequently provides a contribution to solve a practical industrial issue.

Keywords: 316L stainless steel, sintered carbide grain size, wear, cutting temperature, cutting forces, surface
roughness

INTRODUCTION things, their low thermal conductivity and high

ductility [1, 3]. Song et al. [4] emphasize that the
Due to their durability, resistance to corrosion 316L steel has a tendency to work-hardening dur-
and oxidation at high temperatures and very good ing deformation and has a high susceptibility to
hygienic properties, austenitic stainless steels are deformation-induced martensitic transformation.
widely used in many areas of technology. For The attempts to increase the machining parame-
this reason they account for 70% of worldwide ters – cutting speed, feed and depth of cut – cause
market share of all stainless steels [1]. The 316L a significant increase of cutting forces and lead to
steel, which is the subject of this study, belongs defects resulting from residual stress [5]. Fernán-
to 300 series grades of austenitic stainless steels dez-Abia et al. [2] also indicate that poor ma-
which contain 16–26% of chromium and 6–22% chinability of austenitic steels results from their
of nickel. The letter “L“ in the grade designation relatively high friction coefficient at the material–
indicates a low carbon content (about 0.03%), tool interface, high thermal dilation which makes
resulting in a good weldability and exceptional it difficult to maintain machining tolerances and
resistance to corrosion [1, 2]. Unfortunately, the a large area of ductile strain causing very long
machining of stainless steels is a complex and chips and a built-up edge (BUE) on the cutting
difficult process, the reason being, among other tool. Difficult cutting conditions lead to increased

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costs and process emissivity which negatively af- this matter were presented, inter alia, by Kulkarni
fects the process general sustainability and cre- et al., Ciftsi, Endrino et al. [11, 23, 24]. In terms
ates the need for its optimization [6–8]. of tool coatings, the studies are conducted also on
Wear of cutting tools is an important prob- the impact of grain size of the coating on the cut-
lem during the machining of stainless steels. The ting performance of the tools, and the results of
type of wear depends on the values of feed and such studies have been presented by, inter alia,
cutting speed, and consequently on the cutting Bouzakis et al. and Tillmann et al. [25, 26].
forces and temperatures [9]. Large surface pres- Equally important as the studies on the coat-
sures and increased temperatures (e.g. at high cut- ings are studies on the tool substrate structure. In
ting speeds) cause the increased adhesion wear general, cemented carbide consists of WC hard
manifesting itself in formation of built-up edge phase and Co binder phase [27]. It is known that
[10, 11]. According to many authors, in addition hardness and toughness of cemented carbides
to abrasive and diffusion wear, the adhesion wear depend on WC grain size and Co content [28,
is especially critical in the case of machining of 29]. In their work, Bouzakis et al. [30] showed
stainless steels as it may lead to the crater wear, that the finer the grains, the higher the tool sub-
flank wear, chipping and finally to failure of the strate hardness, and the coating deposited on
tool [12–14]. It should be noted that the tool wear such substrate has a better mechanical strength
can affect other output parameters of the cutting than in remaining cases. At the same time, they
process. Martinho et al. [15] concluded that a uni- showed a good adhesion of the coatings on all
form wear of the cutting tool is necessary for a the examined substrate grain sizes. Tang et al.
good surface finish. [31] investigated the relationship between the
In connection with the difficulties mentioned WC grain size, microstructure and properties
above, actions are taken both in industry and of the substrate and coatings. They found that
science in order to improve the quality and ef- the microhardness was similar in all tested and
fectiveness of machining of stainless steels. One that the increase of the grain size in the substrate
common way in this context is an attempt to im- improves bonding strength of the coating. Jian
prove the knowledge and control of the machin- et al. [32] also found a significant impact of the
ing environment and parameters. Many authors substrate grain size on the performance of dia-
presented the impact of parameters such as cut- mond films deposited on tungsten carbide cut-
ting speed, feed, depth of cut on the machined ting tools. Polini et al. [33] showed a major role
surface roughness, cutting force and tool wear of substrate grain size in determining the cutting
[16–18]. Leppert as well as Das and Ghosh [19] performance of diamond coated WC-Co tools;
showed the influence of the cutting zone cooling however they referred only to the tool wear, and
and lubrication on the cutting force as well as on their workpiece was aluminum-based. It is worth
surface roughness and its defects. Szczotkarz et mentioning that the microstructure and therefore
al. [20] by using Minimum Quantity Lubrication mechanical properties of sintered tools can be
(MQL) obtained a significant reduction of the modified by changing the parameters of the sin-
adhesion wear. Natesch et al. [21] proved that tering process. For example, Parihar et al. [34]
the type of lubricating medium also affects the found that the improvement in mechanical prop-
main process outputs. erties (hardness, fracture toughness) of WC-Co
A parallel line in the development comprises sinters can be obtained by increasing sintering
attempts to optimize the design of cutting tools by temperature and heating rate.
using new coatings or tool materials. According The literature review above indicates that
to Inspector and Salvador [22] over 90% of all the knowledge of the impact of the structure of
cemented carbide tools are currently coated with cemented carbines on the properties of tools and
protective layers. AlTiN and AlCrN-based coat- objects manufactured in the machining process
ings are commonly used for carbide tools intend- with the use of such tools needs to be expanded.
ed for machining of stainless steels due their high To the best knowledge of the authors, the studies
hot hardness and oxidation resistance [23]. The on the direct impact of the tool substrate grain
problem of tool coatings and their effectiveness in size on the outputs of the machining process of
the area of machining of difficult-to-cut materials austenitic stainless steels have not been pub-
has been raised by numerous authors and is gen- lished to date. Thus, the research presented in
erally well researched. The results of studies on this paper is novel.

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MATERIALS AND METHODS of rounding of the main cutting edge. In order

to verify this value after the production process,
This section describes the test stand setup, each prototype was measured using an Alicona
the machining process used and equipment and Infinite Fokus microscope. The photographs of
measurement methods applied in the studies. The the microstructure of each sample presented in
last subsection presents the detailed plan of the Figure 2 were taken with the scanning electron
experiment. microscope FEI Quanta 3D FEGSEM integrated

Work material
In the present work, the AISI 316L austenitic
stainless steel has been selected as a work mate-
rial due to its wide applications in many indus-
tries and its poor machinability. The specimens
used were 100×100×50 mm blocks. The basic
mechanical properties of the steel and chemical
composition are presented in Tables 1 and 2, re-
spectively [21].

Milling tools
The tools used in the tests were carbide end
mills of diameter 12.0 mm, working part length
of 26.3 mm and total length of 83.0 mm. The geo-
metrical details are presented in Figure 1. The
milling cutters were made with the use of the
5-axis grinding method from WC-Co sintered
carbide solid bars of various grades: MK12, JF15
and GA20. Before applying protective coatings in
PVD processes, all tools were subject to an ad-
ditional technological procedure in the form of
rounding the cutting edge in order to improve the
durability of the tools. For each tested prototype,
the drag finish process was performed in identi-
cal conditions in order to obtain a similar value

Table 1. General mechanical properties is of the AlSI

316 L
Specification Typical value
Hardness, Rockwell B 95
Ultimate tensile strength (MPa) 485
Yield tensile strength (MPa) 170
Modulus of elasticity (GPa) 200
Poisson’s ratio 0.3
Density (g/cm )
3
7.9 Figure 1. Technical drawing of the milling
Elongation (%) 40
cutters used in the tests. (a), geometric parameters
of the milling cutters used in the tests (b),
Fatigue strength (MPa) 146
visualisation of the designed milling cutter (c)

Table 2. Chemical composition (%) of AISI 316L stainless steel

Element C Mn Si P S Cr Mo Ni N

Wt (%) 0.03 2.00 0.75 0.05 0.03 18.00 3.00 14.00 0.10

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Figure 2. Microstructure of tested tools

with the EDAX Trident analysis system. The Milling process

chemical composition analysis was performed
based on the X-ray energy dispersive spectros- The machining process involved a side mill-
copy, using the ZAF correction procedure. The ing of a 316L steel block according to the dia-
cemented carbide grain size was determined gram presented in Figure 3. The successive steps
with the use of the Feret method. The proposed of the experiment (n) involved the removal of a
tool solution is a prototype created for the needs material layer of a width ap = 20 mm and depth
of machining austenitic steels. As shown by Ta- ae = 1 mm at a constant cutting speed vc = 80 m/
ble 3, the basic parameter that differentiated the min. The feed per tooth was a variable parameter
carbides was the grain size. The GU20 sample whose values were in the range fz = {0.04; 0.06;
had also a more non-homogeneous structure and 0.08} mm/tooth, where z is the number of teeth
an increased content of the Co matrix. in the tool.
All tools were covered with the AlCrN-based
coating BALINIT® ALNOVA made by Oerlikon Test stand, measurement methods
Balzers Coating AG by means of cathodic arc de-
position (Arc-PVD, where PVD means physical The core of the test stand presented in Figure 4
vapur deposition). This kind of coating is recom- was the vertical HAAS MiniMill 2 vertical milling
mended for machining of stainless steels [23]. centre (1) used to perform the machining process.

Table 3. Physical parameters of tested carbides (manufacturer’s data)

Grade Grain size (μm) Cobalt content (wt%) Hardness HRA
MK12 0.18 9.5 92.5
JF15 0.31 9.7 92.3
GU20 0.28 10.4 92.0

Figure 3. Milling process scheme

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Figure 4. S Test stand (1) –HAAS MiniMill 2 milling machine, (2) – thermovision camera, (3) –
dynamometer, (4) –PC with camera operation software, (5) PC with dynamometer operation software

The test stand was equipped with the FLIR measured (measurement area is marked with a
SC620 (2) thermovision camera used to record blue rectangle in Figure 5). The temperature val-
the temperature in the cutting zone. The 640 x ue was recorded on a graph as a function of time.
480 px images were recorded at the 30 fps sam- The cutting forces were measured using a Kis-
pling frequency, and the used emissivity fac- tler 9257B piezoelectric dynamometer (3) mounted
tor was ε = 0.6 [35]. A PC (3) with ThermaCam on the milling machine tool table.. The measure-
Researcher 2.9 software was used to collect and ment setup included a Kistler 5070B charge am-
analyse the measurement data. Figure 5 shows plifier, and the measurement results were recorded
an example of an image obtained. The maximum at 1 kHz frequency on the PC (5) with DynoWare
value of temperature obtained during a given test v.2825A software also provided by Kistler. The cut-
was used in the analysis of data. The maximum ting forces were measured in three perpendicular
value of temperature obtained during a given test directions, however for the preparation of results the
was used in the analysis of data. During the tests, forces measured in the plane perpendicular to the
the maximum temperature in the cutting zone was milling cutter axis were used, i.e. forces Fx and Fy.

Figure 5. Example of image obtained by means of thermovision camera

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The surface finish was evaluated using a machine and Dino Light USB microscope. The
Mahr MarSurf PS10 roughness measuring instru- method of VB determination and an example of
ment equipped with an inductive sliding head microscope photograph are presented in Figure 7.
with the 2 μm tip radius and the contact force of
approximately 0.7 mN. The instrument allows a Experiment design
profilometric measurement of a section at 8 nm
resolution and in the range up to 350 μm. In each The tests were divided into two principal
test, Ra and Rz parameters were measured in parts. The first part of the experiment involved
three equally placed zones over a measurement the determination of the impact of the tool grade
length of 4.8 mm, where the physical measure- on the machined surface finish (Ra, Rz), cutting
ment length was 4 mm, as shown in Figure 6, and forces Fx and Fy and the maximum temperature
the result of each test was their arithmetic mean. in the cutting zone Tmax. The tests were conducted
The tool wear was measured with the use of for three different feed values, and each test was
a DinoLight microscope in combination with a repeated three times, each time with a new tool
Zoller Genius measuring instrument. The parame- to eliminate the impact of the tool wear on the
ter used to evaluate the tool wear was the tool flank obtained results. In total, 27 tests were conducted
wear width VB (mm) which is generally used to as shown in Table 4.
estimate the cutting capabilities of a tool [36, 37]. The second part of the experiment involved
VB mesurement was achived using Zoller genius the impact of the tool substrate grain size and mi-
crostructure on the tool wear. The constant feed fz
= 0.06 mm/tooth was used. The condition of the
edge was checked every 3 minutes and the mill-
ing process was continued until for a given case
the VB reached 0,2 mm (tVB0.2).

RESULTS AND DISCUSSION

Surface finish, cutting forces and cutting

temperature
The results obtained in the first part of the
Figure 6. Method and surface studies are presented in Figures 8 to 10. Figure 8
roughness measurement areas shows the measured surface roughness parameters

Figure 7. Determination of VB (a) and cutting edge photograph (b)

Table 4. Plan of the first part of the experiment

Test No. 1÷3 4÷6 7÷9 10÷12 13÷15 16÷18 19÷21 22÷24 25÷27

Feed fz (mm/z) 0.04 0.06 0.08 0.04 0.06 0.08 0.04 0.06 0.08

Grain size (μm) 0.18 0.18 0.18 0.28 0.28 0.28 0.31 0.31 0.31

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Ra i Rz, Figure 9 describes cutting forces Fx i Fy, The microstructure analysis of used carbides
and the maximum temperatures obtained (Tmax) and the results obtained in this part of the experi-
are presented in Figure 10. In each case, the vari- ment leads to the conclusion that the studied param-
ables on the horizontal axis are carbide (tool) eters are affected not only by the grain size but also
grade and feed per toothThe dots on the graphs by the content of the WC component in the carbide.
represent the mean value from three trials, and The lowest temperatures in the cutting zone
whiskers represent the standard deviations. were obtained for the carbide with 0.31 μm grain

Figure 8. Surface roughness Ra (a) and Rz (b) vs. tool grade and feed fz

Figure 9. Cutting forces Fx (a) and Fy (b) vs. tool grade and feed fz

Figure 10. Maximum cutting zone temperature Tmax vs. tool grade and feed fz

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size (JF15). For remaining carbides, the tempera- Impact of grain size on cutting tool wear
ture values were higher by 10÷25% in compari-
son with JF15 and were maintained at a similar Figure 11 presents the relationship between
level. In case of MK12 (grain size 0.18 μm), the the tool wear VB and the cutting time for vari-
increased temperature in comparison with JF15 is ous carbide grades. All tools were analysed un-
a result of significantly smaller grains. The grain til their wear reached VB=0.2mm. In relation
size defines, in the microscale, the tool-workpiece to the tests performed, each tool performed the
contact area. The smaller the grain, the larger the planned test three times and the cutting edge
contact area and hence the larger the friction and wear referred to the average of the four cutting
the amount of generated heat. In case of GU20, edges tested over the length of contact with the
a similar effect is a result of a higher cobalt con- machined material. Figure 12 shows exemplary
tent which reduces the thermal conductivity of views of edge wear. The tool life was relatively
the carbide and consequently, despite the similar long in case of MK12 and JF15 as it was 183 and
grain size, causes a longer and more local temper- 135 minutes, respectively.
ature concentrations on the friction edge between A common tool wear curve can be divided
the tool and the machined material. Such inter- into three stages, called an initial wear stage, a
pretation of results is in line with more general normal wear stage and a severe wear stage [40].
publications [38, 39]. The impact of feed on the In case of the MK12 tool, these stages lasted
cutting zone temperature is not significant. from 0 to 15 minutes, from 15 to 160 minutes
In all tested cases, the results indicate a relation- and from 160 to 183 minutes. The wear of the
ship between the feed and roughness parameters Ra JF15 tool from the very beginning was uniform-
and Rz. In general, the greater the feed, the higher ly linear until the critical point (~130 minutes),
the values of these parameters. The largest rough- after which the wear progressed very fast and
ness was obtained for JF15 with the largest grain the critical value was reached within the next 5
size. This effect can be attributed to two causes. minutes. No initial wear stage was observed in
Firstly, the smaller grain means a sharper cutting this case which proves a very quick wear of the
edge and, as already mentioned, a larger contact surface structures of the tool. The probable rea-
area between the tool and the workpiece. Secondly, son of this phenomenon is a greater unevenness
as it has been proved, the reduced grain size leads of the cutting edge whose protruding parts wear
to greater cutting forces and so to increased contact quickly and as a result the tool reaches the stabi-
pressures. As a result, the plastic strained surface lized work condition earlier. However, a normal
layer of the material has a lower roughness. wear stage defining the duration of the effective
The cutting forces highly depend on the feed tool work is the longest for the tool with the
value and grow as the feed increases. The radial smallest grain size. In case of GU20, the tool life
force values (Fx) were on average by 40% lower was only 15 minutes. The possible reason is its
than the thrust force (Fy). The least cutting forces non-homogeneous structure which weakens the
were obtained for JF15, and the greatest for MK12. cutting edge. In addition, the increased amount
The differences ranged from about 8% for feed of cobalt matrix in comparison with other tools
fz=0.08 mm/tooth to about 22% for fz=0.04mm/ reduces the tool hardness, consequently increas-
tooth and were similar for both cutting forces. ing its susceptibility to adhesive wear.

Figure 11. Tool wear VB vs. cutting time for various carbide grades

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Figure 12. Exemplary views of cutting edge wear

CONCLUSIONS this carbide for machining of stainless steels in

the conditions of the study.
The studies involved side milling of a cu- 3. The JF15 carbide gave the least cutting forc-
boidal block made of the AISI 316L steel. The es and the lowest temperature in the cutting
machining was conducted with the use of propri- zone. However, it should be noted that the dif-
etary tools made of the WC-Co carbide of various ferences in the obtained results were not sig-
grades, covered with the AlCrN-based coating. nificant (from 10 to 40 %, depending on the
The authors studied the impact of the tool mate- parameter and the carbide type). On the other
rial grade on the maximum cutting temperature, hand, the surface quality was the poorest in
cutting forces, surface finish of the machined sur- this case. The values of Ra and Rz parameters
face and the tool life. The analysis of the obtained were two/three times higher than in case of
results indicates that: the remaining tools. The life of the JF15 tool
1. The studies have proved that the MK12 car- was shorter by 25% than of the milling cutter
bide with the 0.18 μm grain size is the opti- made of MK12.
mal choice for machining of the 316L stainless 4. The feed values did not have a significant im-
steel. This tool had the longest life and allowed pact on the temperatures in the cutting zone,
obtaining the lowest surface roughness pa- however strongly affected the forces. In each
rameters. Although the cutting zone tempera- case, a twofold increase of the feed caused the
ture was highest in this case, it did not exceed Fx force to increase by 40 to 50% and the Fy
200°C and hence did not affect the properties force to increase even by 60%. This trend was
of the machined surface significantly. similar for all tools.
2. The GU20 carbide had the least durability. Its 5. The surface roughness parameters also in-
grain size was 0.28 µm and the cobalt content creased when the feed increased. Depending on
was the highest among all tools. The tool life the tool material, the change of fz from 0.04 to
was less than 15 minutes. The microscopic 0.08 mm/tooth makes the Ra increase twofold.
analysis indicates that this carbide has the most
non-homogeneous structure which, in combi- The findings presented in this article provide
nation with the increased amount of matrix, practical recommendations for improving the
considerably weakens the tool. Despite the low- process of machining stainless steels using tools
est roughness values, it is hard to recommend made of sintered carbide.

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Acknowledgements Manufacturing Technology (2016) 83: 257–264.

11. Ciftci I. Machining of austenitic stainless steels us-
The authors extend their gratitude for assistance ing CVD multi-layer coated cemented carbide tools.
with the experimental studies to Poltra sp. z o.o. Tribol Int (2006) 39: 565–569.
and to Mr. Łukasz Gajos for his technical support. 12. Liu G.J., Zhou Z.C., Qian X., Pang W.H., Li
G.H., Tan G.Y. Wear Mechanism of Cemented
Carbide Tool in High Speed Milling of Stainless
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