1st Edition

Thin-Films for Machining Difficult-to-Cut Materials Challenges, Applications, and Future Prospects

    118 Pages 65 B/W Illustrations
    by CRC Press

    This book presents a balanced blend of fundamental research such as principles and characteristics of machining of difficult-to-cut materials and coating techniques and in-depth practical information on coatings techniques and classifications, the effect of coating parameters on machining responses, and finite element analysis of the machining performance of coated tools. In addition to the benefits of the thin-film deposition on the cutting tools, the limitations of the coating deposition techniques and the coating properties are also discussed.


    • Associates the application of coating technology for improving machining characteristics of difficult-to-cut materials
    • Elaborates effect of coating architecture on the output machining parameters
    • Explores the performance of coated cutting tools
    • Discusses advanced coating systems and their application
    • Includes industrial case studies and practical implementations where coatings were applied for the machining of difficult-to-cut materials

    This book is aimed at researchers and graduate students in thin-films, coatings, machining, materials engineering, and manufacturing.

    1. Introduction to machining

    1.1 Mechanism of chip formation

    1.2 Different metal cutting operations

    1.3 Difficult-to-cut materials

    1.4 Cutting tool materials

    2. Machining Problems and Solutions

    2.1 Machining difficulties and challenges

    2.2 Available remedies to machining difficulties

    2.3 Need of thin-films in machining

    3. Coatings technologies

    3.1 Physical vapour deposition

    3.2 Chemical vapour deposition

    3.3 Hybrid deposition techniques

    4. Classification of Coatings

    4.1 Generation of coatings

    4.2 Classification based on coating material

    4.3 Classification based on coating properties

    4.4 Classification based on coating architecture/design

    5. Application of coatings for Machining

    5.1 Hard coatings

    5.2 Low friction coatings

    5.3 Application of hard and soft coatings hybrid

    5.4 Application of duplex coatings

    5.5 Other combinations

    5.6 Limitations of Thin-films for machining of difficult-to-cut-materials

    6. Effect of coatings on machining parameters

    6.1 Effect of coating thickness

    6.2 Effect of coating architecture/structure

    6.3 Performance of coated tools under coolant/lubrication

    7. Significance of Finite element analysis in analysing performance of coated cutting tools

    7.1 Study of machining forces and stress distribution

    7.2 Study of temperature distribution

    7.3 Chip morphology analysis

    8. Conclusions


    Ch Sateesh Kumar completed his PhD at the National Institute of Technology, Rourkela, India. He worked as Visiting Assistant Professor at the Thapar Institute of Engineering and Technology, India. Later he joined the Advanced Materials Group at the Czech Technical University, Prague, Czech Republic as Postdoctoral Researcher. Presently he is working as a Senior Researcher at the Aeronautics Advanced Manufacturing Centre, Bilbao, Spain in the Department of Mechanical Engineering, Madanapalle Institute of Technology and Science, India. Also, he is working as a Senior Research Associate in the Department of Mechanical and Industrial Engineering Technology, University of Johannesburg, South Africa. His research interests include machining, surface modification techniques, coating deposition and characterization, and tribology. He has published 21 research articles in highly reputed journals and also presented his work at seven renowned conferences. As per Google Scholar, his h-index and i10-index are 10. He has also extended his services as a reviewer in many reputed journals.

    Filipe Daniel Fernandes is currently an Assistant Professor at the School of Engineering at the Polytechnic of Porto, Portugal. In parallel, he integrated the body researcher group of IPN – Instituto Pedro Nunes, where he collaborated in the planning, preparation, and submission of project proposals to different funding entities. He is also a collaborator at the University of Coimbra, Portugal. In 2017 he was awarded a postdoc grant from FCT (SFRH/BPD/116334/2016) having as host institution the University of Minho, Portugal, where he improved the machinability of Ti alloys through the development of novel physical vapor deposition (PVD) films. He was placed in first place among 68 candidates. His work was recognized at the International Conference on Plasma Surface Engineering (Early Career Award 2018), perhaps the most known international conference on surface engineering held in Europe. In 2019 he won the prestigious Marie Curie fellowship and joined the Advanced Materials group at the Czech Technical University in Prague. Since 2010, Filipe Fernandes published 52 articles in international journals, being the first author in 17 of them (one as sole author) and in 21 manuscripts as the last author (four in in-press condition), showing a strong level leadership of his small group (currently one postdoc and one PhD; and one PhD already defended). According to Scopus, currently his h-index is 15 with a total of 607 citations. He is/was a member of the advisor committee/scientific commission of conferences, member of evaluation committees of research projects, member of scientific societies, member of the editorial board of scientific journals, and member organizer of seminars for high school students and graduate researchers. He participated in several national and European research projects; he is currently the PI of the MCTool21 project at the University of Coimbra, Portugal. He supervised and is supervising PhD and master’s students. He was a jury member Jury for PhD and master’s theses. This year he became a father.