Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

Machinability Study of Laser Surface Treated 15-5

PH Stainless Steel

D. Palanisamy & P. Senthil

To cite this article: D. Palanisamy & P. Senthil (2015): Machinability Study of Laser
Surface Treated 15-5 PH Stainless Steel, Materials and Manufacturing Processes, DOI:
10.1080/10426914.2015.1103871

To link to this article: http://dx.doi.org/10.1080/10426914.2015.1103871

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Oct 2015.

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 Machinability study of laser surface treated 15-5 PH stainless steel

D. Palanisamy1 , P. Senthil2

1
Research scholar, Department of Production Engineering, National Institute of
Technology, Tiruchirappalli, 2 Assistant Professor, Department of Production
Engineering, National Institute of Technology, Tiruchirappalli

Corresponding Author to P. Senthil: E-mail: [email protected]

Abstract
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In this work, 15-5 PH stainless steel which is one of the hard to machine materials has

been selected to investigate the machinability characteristics under dry cutting condition

with the aid of laser surface treatment process. Turning experiments were performed on

the laser surface treated 15-5 PH samples with TiAlN coated tungsten carbide inserts.

Machinability of both as received and laser surface treated samples were evaluated in

terms of microstructure, microhardness, tangential cutting force, surface roughness, chip

morphology and tool wear. Experimental consequences revealed that laser surface treated

sample exhibits a remarkable effect on microstructure and microhardness. From the

parametric analysis, it is found that machining of laser surface treated samples are

beneficial in terms of reducing cutting force and are effective in prolonging tool life when

compared with that of as received samples.

KEYWORDS: Laser, surface, treatment, microstructure, micro-hardness, CNC,

Machinability

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 INTRODUCTION

Precipitation hardenable (PH) stainless steel contains chromium and nickel that offer the

characteristics of both austenitic and martensitic phases. PH stainless steels can be

hardened by the aging process which provide high strength and toughness with good

corrosion resistance. Hence, it has been used in numerous applications that includes valve

parts, aircraft fittings, gears, components of nuclear reactors, impellers, etc. [1, 2]. The

investigation on dry machining of nitrogen alloyed duplex stainless steel revealed that the
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cutting forced increased while increasing feed rate due to more contact of material with

tool which increase the resisting force. A minimum cutting force was obtained for the

combined output of lower rate of feed and higher cutting speed [3]. An investigation on

AISI H11 hardened steel with CBN tool by turning experiments stated that the cutting

speed and feed rate had significant effect on tangential force over thrust force. Moreover

smaller hardness of work material resulted in less tangential force [4]. It was found that

the material hardness was prominent factor affecting the cutting force besides cutting

speed and rate of feed, while the thrust force was more impassioned to tool rake angle

and material hardness during machining of AISI 52100 steel [5]. It was found that the

surface integrity microhardness decreased and depth of hardening increased with

increasing cutting speed after machining two-phase duplex stainless steel with coated

carbide insert. Moreover, rounded cutting edge of carbide tool increased both the

microhardness and hardening depth. Also, intermediate ceramic coated tools exhibited

improved microhardness at both surface and depth compared to that multilayer ceramic

coated tool [6, 7].

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 Tool notch wear due to attrition and adhesion wear mechanism was studied while

machining of duplex stainless steel by coated carbide insert. It was found that the

furrowing effect of burr formed at tool-work contact region eroded the coating on tool

insert which aggressively promote the tool wear [8]. The impact of cutting parameters on

coated tool life were assessed during wet turning of duplex stainless steel and revealed

that abrasion wear mechanism which was dominant that lead tool wear at higher feed

rates [9]. Machinability of AISI 4340 alloy steel with coated carbide tool was analyzed
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which disclosed that the rate of feed was the most significant parameter that influencing

on cutting force and tool wear. The tool wear due to higher pressure and temperature at

the cutting zone was evident to abrasion of tool and adhesion of work material [10]. In

order to improve the machinability of hard materials, hybrid process of machining has

been successfully adopted.

Thermal enhanced machining (TEM) is mainly focused on hard to machine materials of

high hardness and strength. Laser assisted machining (LAM) has great potential in

improving productivity, increasing tool life and also advantageous in terms of reducing

cutting forces [11]. An exploration has been performed using LAM and thermal assisted

machining of 17-4 PH stainless steel and Ti-6Al-4V to reveal the tool wear process

during machining and concluded that LAM reduces the cutting force and tool wear, when

compared with conventional machining [12, 13]. It was reported that during LAM of

AISI D2 tool steel, reduction in cutting forces improvement in tool life and formation of

saw tooth chip were observed [14]. LAM increased the material removal rate and reduced

the cutting forces due to the drop in hardness and yield strength of the base material [15-

3
 17]. LAM eliminated the work hardening effect that leads to lower notch wear and

sudden tool failure, it was also stated that LAM increased tool life with better surface

roughness [18]. Chikarakara et al. [19] experimentally investigated the effect of CO 2

pulsed laser on the microstructure and surface roughness of AISI 316L stainless steel. It

was found that the microstructure seems to be uniform and displayed lower roughness

levels. Hongtao Ding et al. [20] studied the effect of laser treatment at the surface and

subsurface in terms of microstructure, micro hardness and surface finish. It was found
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that the parts produced by LAM have good surface finish with uniform surface hardness

and without any microstructural changes.

In practical application, LAM has certain safety restrictions while integrating with

machine tool which reduces the operational efficiency in mass production. Moreover, it is

highly important to ensure that there is no heat affected zones exists after LAM, else the

part may not function appropriately in service. With an approach of machining hardened

steel with ceramic tool, it was stated that the laser tempering based turning process

reduces the cutting forces and surface finish [21]. Mahmoudi et al. [22] studied the

influence of overlap ratio on different laser treatment parameters on the hardness towards

the depth and across the processed area of AISI 420 stainless steel. It was revealed that

the surface hardness decreased in the range of 500–250 HVN to a certain depth which

majorly depends on the laser scanning speed. Chengwu Yao et al. [23] concluded that

laser overlapping results in tempering of martensite steel. It was also revealed that during

overlapping, the formation of martensite during the first pass may be decomposed by the

second pass if it is below the austenization temperature. Venkatesan et al. [24]

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 summarized the potential of LAM for harder materials and it is made known from the

review, that the additional investigations has to be performed on the optimal selection of

laser process parameters to increase the overall productivity.

Laser surface treatment (LST) is a suitable method for treating a desired zone without

affecting the surrounding areas due to its high precision and flexibility. The heating effect

is highly localized and hence the depth of processing can be easily controlled and the
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mechanical properties of untreated bulk materials are retained. It is observed from the

literatures, that there are limited credible work available on machinability study

correlated with LST on PH stainless steels. The objective of this present study is to

compare the machinability of laser surface treated sample with the as received 15-5 PH

stainless steel using coated tungsten carbide insert and to evaluate the tangential cutting

force, surface roughness, tool wear and chip formation. Initially the workpiece is

subjected to different laser scan speeds followed by micro hardness measurement on the

surface and subsurface. Minimum hardness at the surface and subsurface of the sample

by LST process was chosen for further experimental investigation and comparison.

MATERIALS AND METHODS

The workpiece material selected for the present investigation was commercially available

15-5 PH stainless steel. Table 1 shows the chemical composition in wt. % of 15-5 PH

steel. The sample size of 25 mm diameter and 120 mm length with a hardness of 359±4

HV0.5. was considered for this study. A CO2 continuous wave laser (Trumpf TLC 1005)

with a maximum power of 2400 W was used for the surface treatment of work samples

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 and the schematic diagram of LST process was shown in Fig. 1. The laser spot size was 5

mm and the rotational speed of workpiece was 25 rpm. To obtain better laser

performance and optimum scan speed, various experimental trials was performed under a

wide range of laser scan speed from 1.0 to 1.5 m/min. The temperature was measured by

using ITIP 400 infrared camera. Abrasive cutter was used to section a sample from LST

workpiece to measure microhardness and microstructure analysis as shown in Fig. 2.

Surface and sub- surface micro hardness tests were conducted in the Vickers hardness
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machine (Wolpert Wilson Instruments) with a dwell period of 10 seconds. The first

indentation of microhardness was located at the circumference of the LST sample and the

subsurface hardness were measured towards the depth along a straight line perpendicular

to the LST surface. The distance between the successive indentations was 50 µm and then

continued until the base material hardness reached. Optical microscope (Olympus

Microscopy) was used for observing the microstructural variation and tool wear. Sample

preparation for optical microscope was done using standard metallographic techniques

and Fry’s reagent was used as an etchant.

Turning experiments were conducted in a CNC turning machine under dry condition for

both as received and LST samples. A tool holder and insert having ISO designation of

PCLNL 1616 H12 and CNMG 120408-GM were used for machining. TiAlN coated

tungsten carbide inserts with tool geometry of clearance angle (α) =5°, inclination angle

(η) = -6° side rake angle (γ) = -6°, approach angle (ψ) = 95°, point angle (β) = 80° and

nose radius (r) =0.8 mm were used in this present investigation. Tangential cutting force

(Fz) were measured with KISTLER make 9257 B type dynamometer. Average surface

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 roughness (Ra) values were measured using Mitutoyo SJ 410 surface roughness tester.

The 3D surface profile was taken using a white light interferometer (Rtec instruments).

The operating range of machining parameters and their levels were taken from the

available literature [2]. An L9 orthogonal array was used for designing the experiments

and the details of machining parameters are presented in Table 2.

RESULTS AND DISCUSSION

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A set of experiments has been performed based on L 9 orthogonal array. Micro-hardness,

cutting force, surface roughness and tool wear were considered as performance measures

and microstructure and chip formation were also analyzed for all the machined samples.

Effect Of Laser Surface Treatment On Hardness At The Surface And Sub-Surface Of

PH Stainless Steel

During LST, at scanning speed of less than 1.2 m/min, workpiece started melting due to

higher overlap ratio, which induces the increase in temperature at the surface. The

hardness of 15-5 PH material after laser surface treatment with varying scan speeds (1.3,

1.4 and 1.5 m/min) is presented in Fig. 2. Variation in hardness was observed for

different scan speeds. In all the laser scanned samples the hardness were measured for a

length of 0.6 mm from the circumference towards the depth of the bulk material. From

the Fig. 2, it is observed that the hardness was lower for the scan speed of 1.4 m/min

when compared with the other scanning speeds. The hardness at the surface and sub-

surface is reduced due to the tempering effect of the overlapping laser scan [21-23].

Moreover, the reduction in hardness is due to the laser power and optimal scan speed that

7
 controls the heat energy imparted to the workpiece.

The hardness was found higher from the surface to subsurface for the sample treated at

scan speed 1.3 m/min than 1.4 m/min. This increase in hardness is due to the more

interaction time of heat input at lower scan speed and hence more heat energy is

absorbed. At the scan speed of 1.5 m/min the hardness was higher than the other scanning

speeds due to the insufficient temperature to make the material soften. The scan speed 1.4
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m/min produces lowest hardness than the other scanning speeds. Hence, the workpiece

treated with 1.4 m/min is chosen for the machining experiments.

Effect Of Laser Surface Treatment On Microstructural Analysis

The depth of tempered region depends on the overlap ratio and it can be increased or

decreased by suitable selection of the laser scan speed conditions. From the Fig. 2, it is

found that the scan speed 1.4 m/min produces lowest hardness than the other scanning

speeds. Hence it is believed, that the scanning speed of 1.4 m/min provides the

appropriate temperature that results in optimal interaction time of the laser at the

circumference of work piece which could promote the good decomposition. The

microstructure of the cross sectioned work piece exposed to laser irradiation of 2400 W

power, 5mm spot size and at scanning speed of 1.4 m/min is shown in Fig. 3.

The temperature at the circumference of the work piece during laser surface treatment

was measured in the range of 760 – 810 °C. It is observed that the laser irradiation made

a remarkable effect on the microstructure of the work piece. From the microstructure,

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 three distinct regions, namely (i) laser surface treated zone (ii) heat affected zone and (iii)

base material zone is observed. Also from the Fig. 3, the light region shows, laser surface

treated zone and darker region reveals the base structure of the martensitic 15-5 PH

stainless steel. The light region strongly reflects the complete decomposition reaction of

coherent copper precipitates to incoherent FCC-Cu particles [12]. On the other hand, an

intermediate region (heat affected zone) with dark and light region mixture is observed,

which shows the poor interaction of laser irradiation with the work piece thus cause the
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lower decomposition of coherent copper precipitates due to lesser penetration of the laser

beam. Furthermore, there is no alteration in the microstructure of the base material, which

confirms that there is no interaction occurred in between laser and work piece after a

certain depth from the circumference. The above results are in good agreement with the

available literature [21 - 22].

Effect Of Laser Surface Treatment On Cutting Force

The measured values of tangential cutting force of as received sample and LST sample

are given in Table 3. The interaction effects of machining parameters on tangential

cutting force (Fz) for the LST samples and as received samples of 15-5 PH stainless steel

is shown in Fig. 4 (a & b). The tangential cutting force was observed to be less for the

given machining condition and also the material removal is quiet easier for the LST

sample compared with as received sample due to lower hardness at the surface [15–17,

21]. An average reduction in tangential cutting force of about 9 % was observed in the

machining of LST sample.

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 For all the selected parameters the tangential cutting force reduced with an augmentation

of cutting speed during machining of as received and LST samples. Fig. 4 (a) shows the

influence of feed rate at low level (0.05 mm/rev) on cutting force at various cutting

speeds (100-200 m/min). For the both as received and LST sample with cutting speed at

low level (100 m/min) and feed rate at low level (0.05 mm/rev) the cutting force was

higher and dropped during an increment of cutting speed to 200 m/min. The reduction in

cutting force with an augmentation of speed of cutting is owing to the rise in temperature
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that cause thermal softening in the cutting zone. There is a reduction of friction at the tool

chip interface due to rise of temperature. A similar trend of reduction in cutting force

with increase in speed were observed for the other set of feed rates 0.10 and 0.15 mm/rev.

Increase in rate of feed results in increased cutting force for the both as received sample

and LST samples. The range of cutting force at low cutting speed 100 m/min and low rate

of feed 0.05 mm/rev was 72.47 N for the as received sample and 64.77 N for the LST

sample. As the rate of feed increased to 0.15 mm/rev the cutting force increased to 111.56

N for the as received sample and 104.79 N for the LST sample as shown in Fig. 4 (b).

Similar trend has been observed for the other set of machining parameters 150 m/min and

200 m/min. It is made known from the analysis that the cutting force is escalated with

augmentation of rate of feed than cutting speed during machining and is due to increase

in area of contact between the tool and workpiece interface. At low feed rate the

resistance offered by the workpiece on the tool is less and hence friction at the tool-work

interface is less. At higher feed rate, the rate of material removal is high. The resistance

offered at this condition is more which increases the friction and hence the cutting force

10
 is high. Moreover, for all the machining parameters the cutting force was high for the as

received sample than the LST sample. The lowest cutting force of 54.62 N was observed

for the LST sample at a cutting speed of 200 m/min, with feed rate at the level of 0.05

mm/rev. The above outcomes were in good agreement with the available literature [11,

14 and 21].

Effect Of Laser Surface Treatment On Surface Roughness

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The measured surface roughness value of LST sample and as received sample are shown

in Table 3. The difference in measured roughness value depends on the machining

parameters, workpiece hardness and sample condition. The interaction effects of

machining parameters on surface roughness (Ra) for the laser surface treated and as

received sample is shown in Fig. 5. It is observed from the table that the average surface

roughness value for as received sample is less than that of the LST sample for all

experimental conditions. In general the surface roughness mostly depend on feed rate and

cutting speed. Fig. 5 (a & b) shows the graphical representation of roughness of machined

surface at distinct levels of feed rates and cutting speeds. Fig. 5 (a), shows the influence

of low rate of feed (0.05 mm/rev) on surface roughness at various cutting speeds in the

range of (100 - 200 m/min). During machining at low rate of feed (0.05 mm/rev) and

cutting speed at low level (100 m/min) the roughness of machined surface were high for

the both as received and LST sample and there is a decrement during an escalation of the

cutting speed to (200 m/min). When the speed increases the cutting temperature at the

tool work interface increases, which soften the workpiece material. This thermal

softening leads to lesser ploughing force, thereby ease of material removal and resulted in

11
 a better surface finish.

Similar trend of decrease in surface roughness as the speed increased were observed for

the other range of feed rates 0.10 and 0.15 mm/rev. From the comparison between

influence of feed and speed at various conditions, it is found that the surface roughness

(Ra) of as received sample is less compared to that of LST sample. As presented in Fig. 5

(b), it is found that there was an increase in surface roughness as the feed rate increased.
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During machining at low feed rate the vibration is minimized and the cutting force is less.

But at higher feed the vibrations and chatter marks on the machined surface is more that

results in higher surface roughness. Similar trend were observed for the feed rate of 0.1

mm/rev and 0.15 mm/rev. The variation in surface roughness value of the as received

sample which has higher hardness at the surface than the LST sample, is due to smaller

grain size, which cause lesser crater during material removal in machining [25].

Moreover the presence of feed marks on the machined surface of LST sample induces the

poor surface finish. Comparing all the experimental conditions for the both as received

and LST sample the surface roughness are found to be better during machining at higher

speed (200 m/min) and at rate of feed at low level (0.05 mm/rev). The above discussions

are in good agreement with the available literature [21, 22 and 25].

The surface topography of both as received and LST samples at a speed of 200 m/min

and feed 0.05 mm/rev were shown in Fig. 6 (a & b). The 3D image has covered a

distance of about (2.9 X 2.3 mm) of the machined surface. The reduced peak and valley

of 170 µm and 30 µm were observed in the as received sample as seen in Fig. 6 (a). The

12
 maximum peak of 260 µm and the lowermost valley of 130 µm were observed for the

LST sample as found in Fig. 6 (b). The 3-D surface topography with smaller amplitude

was observed in the as received sample than the LST sample which specifies that the

surface is uniform and the surface roughness is better.

Chip Form Analysis

Different morphology of chips are found while machining of both the as received and
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LST sample for given cutting conditions as shown in Fig. 7. At almost all cutting

conditions the chips were found to be saw toothed inferring the hardness of the sample at

the surface. At low speed and low feed long continuous chips with small curl was

observed at low temperature, induced at tool-work interface that causes lesser severe

plastic deformation.

As the rate of feed escalates from 0.05 to 0.15 mm/rev, the chips were seemed to be

helical in shape with large curl radius. Moreover the peak height of the saw tooth

decreased for the both as received and LST sample due to less friction and less ploughing

force. As the speed increases from 100-150 m/min, a similar trend has been evaluated

with decrease in chip width due to lesser friction that exist between the tool-work

interface. When the cutting speed is escalated to 200 m/min, the continuous chips with

uneven curl shape were found due to the combined effect of thermal softening effect and

strain hardening. During the cutting speed and rate of feed at low level, the chip thickness

was high for both LST and as received sample due to smaller shear plane angle and large

contact area on the rake face. Moreover, cutting speed at higher level, the thickness of the

13
 chip is less and the magnitude of the chip segment is decreased due to the higher

temperature at primary deformation zone that makes the material softer. The stiffness of

the chip in as received sample is high due to higher hardness on the surface while

compared to LST samples. The above results are in good agreement with the available

literature [14].

Tool Wear
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The comparison of tool wear while machining as received sample and LST sample for the

given machining parameters with a constant machining length is shown in Fig. 8. It has

been found that, while using coated carbide inserts delamination of coatings starts at the

initial stage of machining then the usual modes of wear mechanism (abrasion, diffusion

and adhesion) appear. The tool wear at low cutting speed was due to abrasion and at

higher speeds the tool wear was due to thermal softening, diffusion and notching [3, 8, 26

and 27].

In machining the as received material, the wear rate was more compared to that of LST

sample due to the abrasive action of micro hard particles present in the work material.

Under all machining conditions the measured flank wear was within the recommended

limit [ISO 3685 standard]. While machining as received sample, due to the effect of high

temperature at the tool work interface the insert is subjected to thermal induced

weakening at the rake face [21].

14
 The flank wear was high while machining as received material, rather it was less for LST

sample. For both the as received and LST sample, abrasion type wear was noticed at low

feed rate and low cutting speed. As the escalation of cutting speed and rate of feed, the

flank wear also increased and this is due to the rubbing action which produces more heat

that makes the tool insert soft at the nose of the cutting edge. However, the contact stress

at the cutting edge is more, hence the flank wear is likely to be more. The material is soft

at the circumference of the LST sample therefore the penetration of tool insert is made
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easier. Hence the flank wear observed were relatively less for LST samples than the as

received samples. The above results are in good agreement with the available literature

[12, 13 and 18].

CONCLUSIONS

In this experimental study, tangential cutting force, surface roughness, chip morphology

and tool life for different machining parameters has been investigated in Laser surface

treated 15-5 PH stainless steel under different scan speeds. The following conclusions are

drawn:

A remarkable change in hardness and microstructure in the surface and subsurface

was noticed for the LST sample. There was a reduction in microhardness for a depth of ~

500µm from the circumference of LST samples.

An average reduction in cutting force about 9 % has been observed for the entire

range of selected parameters under the laser surface treated samples due to the reduction

in hardness when compared with as received samples.

15
 The surface finish seems to be better for the as received samples than the laser

surface treated samples.

In machining of LST samples, the chips are found to be continuous with uniform

saw toothed at higher speeds due to the improved deformability and shearing of the

material by plastic deformation.

The tool wear observed was relatively lower for the LST samples than the as

received samples.
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ACKNOWLEDGEMENT

The authors gratefully acknowledge, The Magod Laser Machining Pvt. Ltd., Bangalore,

India for allowing us to carry out Laser treatment for this research work.

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 Table 1. Chemical Composition of as received 15-5 PH stainless steel

Constituents C Mn P S Si Cr Ni Cu Nb

with

Ta

Weight (%) 0.03 0.78 0.0290 0.010 0.270 15.17 3.97 3.12 0.270
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 Table 2. Machining parameters and their levels

Parameters Level I Level II Level III

Cutting Speed Vc (m/min) 100 150 200

Feed Rate f (mm/rev) 0.05 0.10 0.15

Depth of cut ap (mm) 0.50 0.50 0.50

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 Table 3. Effect of machining parameters on cutting force and surface roughness

Exp. Cutting Feed rate Depth of As received sample LST sample

No speed (f ) cut (ap) (Fz) (Ra) (Fz) (Ra)

(Vc) mm/rev mm

m/min

1 100 0.05 0.50 72.47 0.523 64.77 0.563

2 100 0.10 0.50 92.04 1.137 86.72 1.147

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3 100 0.15 0.50 111.56 1.526 104.79 1.537

4 150 0.05 0.50 69.79 0.429 58.24 0.521

5 150 0.10 0.50 89.81 0.970 83.86 1.022

6 150 0.15 0.50 109.25 1.407 102.91 1.479

7 200 0.05 0.50 63.38 0.286 54.62 0.349

8 200 0.10 0.50 84.81 0.637 74.12 0.655

9 200 0.15 0.50 106.39 1.189 98.09 1.178

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 Figure 1. Schematic diagram of experimental setup of laser surface treatment.
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 Figure 2. Method of sample preparation and Micro hardness of the LST sample
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 Figure 3. Microstructure of laser surface treated samples of 15-5 PH stainless steel.
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 Figure 4. (a-b). Influence of machining parameters on cutting force
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 Figure 5. (a-b). Influence of machining parameters on surface roughness
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 Figure 6. Surface roughness 3D profile at speed 200 m/min and feed 0.05 mm/rev (a) as

received sample, (b) LST sample.

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 Downloaded by [Simon Fraser University] at 07:35 27 December 2015

Figure 7. Chip form analysis

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 Downloaded by [Simon Fraser University] at 07:35 27 December 2015

Figure 8. Comparison of tool wear

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