Thin-Films for Machining Difficult-to-Cut Materials : Challenges, Applications, and Future Prospects book cover
1st Edition

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

  • Available for pre-order on April 20, 2023. Item will ship after May 11, 2023
ISBN 9781032375120
May 11, 2023 Forthcoming by CRC Press
128 Pages 65 B/W Illustrations

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Book Description

This book presents 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 is 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.

Table of Contents

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

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Dr. Ch Sateesh Kumar completed his PhD from National Institute of Technology, Rourkela. He worked as Visiting Assistant Professor in Thapar Institute of Engineering and Technology. Later he joined Advanced Materials Group at Czech Technical University, Prague as Postdoctoral Researcher. Presently he is working as Senior Researcher at The Aeronautics Advanced Manufacturing Centre, Bilbao, Spain in the Department of Mechanical Engineering, Madanapalle Institute of Technology & Science, Also, he is working as Senior Research Associate in the Department of Mechanical & Industrial Engineering Technology, University of Johannesburg, 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 in 7 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 assistant professor at the School of Engineering in Polytechnic of Porto. 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 collaborator at the University of Coimbra. In 2017 he was awarded with a post-Doc grant from FCT (SFRH/BPD/116334/2016) having as hosting institution the University of Minho, where he improved the machinability of Ti Aloys through the development of novel PVD films. He was placed as 1st place among 68 candidates. His work was recognized at the PSE conference (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 Advanced Materials group at Czech technical university in Prague. Since 2010, Filipe Fernandes published 46 articles in international journals, being the first author in 17 of them (one as sole author) and as 21 manuscripts as last author (4 in in-press condition), showing a strong level leadership of his small group (currently 1 Postdoc’s and 1 PhD; and 1PhD’s already defended). According to Scopus, currently his h-index is 14 with a total of 536 citations. He is/was member of the advisor committee/scientific commission of conferences, member of evaluation comities 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 MCTool21 project at the University of Coimbra. He supervised and is supervising PhD and master students. He was member Jury in PhD and Master Thesis. This year he become father.