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Procedia CIRP 77 (2018) 541–544
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8th CIRP Conference on High Performance Cutting (HPC 2018)

Increased tool performance with niobium carbide based cutting materials in

dry cylindrical turning
E. Uhlmann1, D. Hinzmann1*, K. Kropidlowksi1, P. Meier1, L. Prasol1, M. Woydt2
1
Institute for Machine Tools and Factory Management (IWF), Technische Universität Berlin, 10587 Berlin, Germany
2
BAM Federal Institute for Materials Research and Testing, 12200 Berlin, Germany

* Corresponding author. Tel.: +49-(0)30-314-22903; fax: +49-(0)30-314-25895. E-mail address: [email protected]

Abstract

Niobium carbide (NbC) shows promising results as an alternative cutting tool material to tungsten carbide (WC) for turning of iron-based
materials. Due to its hot hardness and low solubility of binderless NbC in solid chrome, nickel, cobalt, or iron, it presents excellent properties
for cutting tool applications. These advantages result in a reduced tendency to adhesive and diffusion wear, which affects cutting tool lifetime
and process stability. In order to investigate a possible substitution of the conventional substrate material tungsten carbide, the BAM Federal
Institute for Materials Research and Testing and the Institute for Machine Tools and Factory Management (IWF) of the Technische Universität
Berlin analyze the suitability of NbC for the use as a cutting tool in turning processes. Two different straight NbC materials are included in the
machining trials prepared by Katholieke Universiteit Leuven, Belgium each differing in chemical composition and mechanical properties. A
cobalt (Co) bonded niobium carbide defined as NbC0.88-12Co, a nickel (Ni) bonded NbC with the specification (NbC1.0-10TiC)-6Ni7.5VC and
a commercially available cermet with a niobium content of wt.-%NbC = 25 % are selected and compared to submicron grain WC-6Co tool
material. Carbon steel C45E and gear steel 42CrMo4+QT are chosen as workpiece materials of different representative technological
applications for dry external cylindrical turning tests. A variation of cutting speed is carried out to show the impact of higher thermomechanical
load during machining. The results evaluate the cutting performance of NbC compared to WC regarding material removal VW and crater wear
KT. In contrast to WC tools NbC cutting tools show constant material removal VW at increased cutting speed vc combined with a higher
process reliability.

© 2018 The Authors. Published by Elsevier Ltd.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the International Scientific Committee of the 8th CIRP Conference on High Performance
Cutting (HPC 2018).
Keywords: Niobium carbide (NbC), tungsten carbide (WC), tool wear, cylindrical turning

1. Introduction can additionally be achieved with the deposition of tool

coating [1].
The market for hard metal tools is currently dominated by Since 80 % of raw material of tungsten is located in China,
tungsten carbide (WC) cutting materials. Compared to high a guaranteed supply for global consumption is subject to
speed steel (HSS) tools, machining operations in industrial Chinese economic policy. This worldwide dependency
manufacturing processes can be performed allowing higher classifies it as a critical resource [2]. Hence, a recent effort for
cuttings speeds vc as well as efficiency enhancement in the an alternative option can be observed focusing on NbC as a
production sector. With constant tool improvement on WC capable high-performance substitution of conventional cutting
dispersed in ductile cobalt binder (WC-Co) in order to opti- material [3,4,5].
mize its diversity of application it is regarded as state of the art The potential of niobium as an alternative cutting material
cutting material. Extended tool life regarding wear resistance far exceeds the typical use as a growth inhibitor in the hard
metal production or as an alloying element in cermets based

2212-8271 © 2018 The Authors. Published by Elsevier Ltd.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the International Scientific Committee of the 8th CIRP Conference on High Performance Cutting
(HPC 2018).
10.1016/j.procir.2018.08.238

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 542 D. Hinzmann et al. / Procedia CIRP 77 (2018) 541–544

on titanium carbon nitride Ti(C,N) [6]. Promising material 2. Cutting materials

properties of niobium carbide (NbC) combined with a
contemporary volatile price development of WC increases the The NbC tools used in this wear investigation are defined
attention as a powerful cutting tool application, see Table 1. as NbC0.88-12Co and (NbC1.0-TiC)-6Ni7.5VC and are manu-
Besides the long term objective to establish NbC as a reliable factured by KATHOLIEKE UNIVERSITEIT LEUVEN, Belgium.
cutting tool material, its classification for biomedical Commercially available WC tools with a 6 % cobalt binder
applications shows the variety for further fields of application. manufactured by EXTRAMET AG, Plaffeien, Switzerland,
Also, in contrast to cobalt, it is not subject to toxicologically denominated as WC-6Co (submicron grain), serves as the
relevant labelings or classifications. industrial reference commonly used in production. WC with a
mass fraction of cobalt binder wWC = 6 % contains an equal
Table 1. Comparison of material properties between WC and NbC [7]. volumetric fraction of binder material compared to the NbC
Property WC NbC Effect cobalt content wNbC = 12 % due to the 50 % lower
Density ρ 15.63 7.78 Reduction of centrifugal density ρNbC.
[g/cm³] forces in rotating and The cobalt bonded and substochiometric straight NbC0.88
dynamic tools was manufactured by Spark Plasma Sintering (SPS) with an
Melting point Tm 2870 3520 Less weakening of the initial primary grain size of dNbC0.88 = 150 nm at holding
[°C] cutting edge at high cutting temperature THS = 1285 °C and sintering time of ts,SPS = 6 min
temperatures
at a pressure of pSPS = 30 MPa.
Oxide layer WO3 Nb2O5 No sublimation of tribo- For the manufacturing process of the nickel bonded NbC
chemically stable Nb2O5 with
containing titanium carbide (TiC) and vanadium carbide (VC),
high melting point at
Tm,Nb2O5 = 1522 °C stoichiometric NbC1.0 powder with an initial primary grain
size of dNbC1.0 = 350 nm was processed in conventional sinte-
Sublimation of WO3 at
approx.Tm,WO3 ≈ 700 °C ring (CS) at a temperature of tCS = 1420 °C and sintering time
of ts,cs = 60 min at a dynamic vacuum of pCS = 20 Pa.
Thermal 84 14 Lower heating of NbC
conductivity λ during machining leads Tools composed of WC-6Co are manufactured via hot
[W/m∙K] to reduction of thermally isostatic compression (HIP) under industrial conditions. The
induced wear differing microstructure of each substrate is attributed to the
Microhardness 20 - 15 - Higher hot hardness of NbC varying sintering process, see Figure 1.
[GPa] 28 20 at elevated temperatures
as of approx. TH ≈ 900 °C
Solubility in solid Reduction of chemical
(crater-) wear during
Nickel, 12 3
Cobalt, 22 5 machining of materials with
alloying elements nickel,
Iron 7 1
cobalt, iron
at T = 1250 °C [wt.-%]

In order to resist wear mechanism such as adhesion, abra- Fig. 1. Microstructure of a) WC-6Co,
b) NbC0.88-12Co and c) (NbC1.0-10TiC)-6Ni75VC.
sion, tribomechanical wear and surface attrition in machining
operations, tools require high hardness and toughness.
WC tools benefit from the elaborated industrial manufactu-
Additionally, high mechanical strength as well as thermal and
ring process highlighted by the equal and homogenous
chemical stability is required to meet the conditions in high
distribution of binder and hard phase as well as small grain
performance machining and ensure process stability.
size. In contrast, both NbC tools lack homogeneity in distri-
Due to a lower solubility of binderless NbC in solid chrome
bution of substrate material and reveal coarse grains due to the
(Cr), nickel (Ni), cobalt (Co) and iron (Fe) compared to WC, a
laboratory scale of production.
reduced chemical wear on the rake fake is expected [7]. The
The manufactured cutting tools offer differing mechanical
higher melting point of NbC with TM = 3520 °C linked with a
properties due to the varying sintering process and the compo-
lower solubility in alloys reduces adhesion with the workpiece
sition of the cutting materials, see Table 2.
during machining [8]. Further advantageous properties such as
a lower wear rate caused by friction at elevated speeds and a Table 2. Mechanical properties of WC and NbC [11].
higher hot hardness as of T ≈ 800 °C of substochiometric and Cutting material Vickers hardness Fracture 4-point bending
stoichiometric NbC substrates compared to WC-6Co have HV 30 toughness KIC* strength σ4pb
been reported [9,10]. Taking into account the conditions in [MPam] [MPa]
machining operations based on thermomechanical loads, NbC WC-6Co 1790 9,60 N.A.
displays the capacity as a cutting tool for a variation of steel NbC0.88-12Co 1499 5,78 1005
based workpiece materials. (NbC1.0-10TiC)- 1360 7,99 626
6Ni7.5VC

*KIC = Palmqvist method with Shetty´s equations

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 D. Hinzmann et al. / Procedia CIRP 77 (2018) 541–544 543

A lower hardness on both NbC substrates compared to WC val VW compared to WC-6Co. At elevated cutting speeds
substrate material cannot be linked with a lower wear of vc = 100 m/min and vc = 150 m/min, NbC0.88-12Co tools
resistance. Amongst others, the mechanical strength tested by occasionally confirm the before mentioned potential even
4-point bending tests needs consideration in order to compile a though an average decrease of material removal VW by 20 %
tribomechanical profile for a cutting material [11]. and subsequent 30 % respectively can be observed. Sponta-
After sintering NbC0.88-12Co and WC-6Co tools are produ- neous tool failure at elevated cutting speeds vc = 100 m/min
ced according to ISO geometry SPUN120408 and CNMN and vc = 150 m/min limits the overall process stability.
120408 regarding its later application for workpiece machi- (NbC1.0-TiC)-6Ni7.5VC meets the requirements as a cutting
ning. Besides SPUN120408 tools then analogous geometry tool alternative by exceeding the material removal rate of WC
CNMN090308 of (NbC1.0-10TiC)-6Ni7.5VC cutting inserts at all cutting speeds vc. The mean value of the material
are produced due to limitations of raw material. Identical tool removal VW increases by 60 % at vc = 100 m/min and subse-
engagement conditions of all cutting inserts in machining quent 2.5 % at vc = 150 m/min with a simultaneous increase in
trials are maintained ensuring an overall comparability. process stability.
For machining tests with SPUN120408 tools an entering
angle of κ = 75 °, an orthogonal rake angle of γ0 = 6 °and an Process: Machine tool:
Dry longitudinal cylindrical turning DMG CTX gamma 1250 TC
inclination angle of λs = 0 °are chosen. CNMN090308 tools Workpiece materials: Process parameter:
are implemented with an entering angle of κ = 95 °, an C45E f = 0.1 mm
ap = 0.5 mm
orthogonal rake angle of γ0 = -6 °and an inclination angle of 42CrMo4+QT (53 HRC) f = 0.1 mm
λs = -6 °. ap = 0.3/0.2 mm
Wear criteria:
Prototype based tool manufacturing of NbC tools caused VBmax = 0.2 mm
occasional irregularities such as roughness or breakouts on the Tools:
cutting edge which affected the cutting edge quality. In order WC-6Co EMT100, untreated
NbC0.88-12Co SPS, brushed
to guarantee equal cutting tool features between NbC and WC (NbC1.0-10TiC)-6Ni7.5VC CS, brushed
tools, an additional brushing process on NbC inserts produced 80
identical cutting edge conditions [12]. A reduction of minor C45E 42CrMo4+QT
Material removal Vw

breakouts and levelling of cutting edge roughness Ra as well mm3

as cutting edge radii rß provided comparable inserts.

40

3. Experimental setup 20

The turning tests were performed on a DMG MORI AG, 0

70 100 150 70 100 150
Bielefeld, Germany machining center CTX gamma 1250 TC.
Cutting speed vc [m/min]
The assessment of the cutting materials was carried out via dry
longitudinal cylindrical turning. According to ISO 3685 the Fig. 2. Material removal VW comparison of WC, NbC0.88-12Co and
(NbC1.0-TiC)-6Ni7.5VC in machining of C45E and 42CrMo4+QT.
maximum wear width VBmax = 0.2 mm and crater wear
depth KT are used for quantitative wear evaluation [13]. By
Apart from the evaluation of the material removal VW the
interrupting the cutting process at fixed intervals of
chemically induced crater wear was also quantitatively
tI = 5/15/30/60 s, the measurement of the flank wear was
assessed, see Figure 3.
realized. In each case, three machining trials (n = 3) for all
The low solubility of iron in NbC is reflected in the low
combinations of cutting material, workpiece material and
crater wear measurements after machining, both C45E and
cutting speed vc were performed.
42CrMo4 Q&T. While machining C45E the crater wear for
WC-6Co tools increases by a total of 82 % at higher cutting
4. Results
speeds vc = 100 m/min and subsequent 180 % at vc = 150
m/min. In contrast to the conventional cutting material WC,
Machining trials with carbon steel C45E as well as harde-
NbC grades resisted the thermo-mechanical load. Technical
ned, quenched and tempered steel 42CrMo4+QT showed the
advantages of NbC substrates for the investigated machining
potential of NbC as a capable cutting materials substitution of
operations are based on the chemically stable property combi-
WC, see Figure 2.
ned with a low friction coefficient. Even under high perfor-
Machining tests with NbC0.88-12Co offer an approximated
mance conditions all NbC tools, varying in binder material,
constant material removal VW of C45E with increasing cutting
additives and sintering condition, attest the capability as a
speed, establishing a continuous increase in process stability.
cutting tool for the tested workpiece materials. Compared to
Identical tool behavior can be attributed to (NbC1.0-10TiC)-
NbC tools, an eightfold higher measured crater wear depth KT
6Ni7.5VC cutting inserts exceeding the mean material remo-
on the cutting tools rake face of WC inserts support the appli-
val VW of NbC0.88-12Co and WC-6Co tools at all cutting
cability of this novel cutting material in machining of carbon
speed variations. In addition, the reliability of this machining
based workpiece materials.
operation is demonstrated at the highest cutting speed due to
the achieved process reliability.
While turning 42CrMo4+QT at vc = 70 m/min,
NbC0.88-12Co demonstrates a fourfold higher material remo-

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 544 D. Hinzmann et al. / Procedia CIRP 77 (2018) 541–544

Process: Machine tool: 6. Conclusions

Dry longitudinal cylindrical turning DMG CTX gamma 1250 TC
Workpiece materials: Process parameter:
C45E f = 0.1 mm NbC-based tools demonstrated great potential in turning of
ap = 0.5 mm
42CrMo4+QT (53 HRC) f = 0.1 mm iron-based work pieces. Compared to industrial WC-6Co,
ap = 0.3/0.2 mm NbC substrates multiply the tool life when machining carbon
Wear criteria:
VBmax = 0.2 mm steel C45E and quenched and tempered steel 42CrMo4+QT.
Tools: However, the current straight NbC inserts from laboratory
WC-6Co EMT100, untreated scale with limited homogeneities displayed occasional prema-
NbC0.88-12Co SPS, brushed
(NbC1.0-10TiC)-6Ni7.5VC CS, brushed ture tool failures.
100 By adjusting the metallurgy and processes including sinte-
C45E 42CrMo4+QT ring cycles of NbC, significant gains in toughness and strength
µm can be achieved and are scheduled for further investigation.
Crater wear KT

The optimization of micro-geometry represents another impor-

50
tant task for NbC. Additional steps focus on wear resistant
25 tool coatings and tool geometry adjustments in order to obtain
improved tool performance and enhance tool life and process
0 stability.
70 100 150 70 100 150
Cutting speed vc [m/min]
Acknowledgements
Fig. 3. Crater wear comparison of WC, NbC0.88-12Co and
(NbC1.0-TiC)-6Ni7.5VC in machining of C45E and 42CrMo4+QT.
The authors thank the COMPANHIA BRASILEIRA DE
METALLURGIA E MINERAÇÃO (CBMM), São Paulo, Brazil, for
5. Discussion providing NbC for tooling and the GERMAN RESEARCH
FOUNDATION (DFG) by project UH 100/186-1 for financial
Two NbC substrates were compared to industrially esta- support.
blished WC-Co hard metal in dry machining of carbon steel
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