I wish to test a hard coating on simple geometry tools (e.g., indexable carbide inserts). Can anyone recommend a material and machining operation which should readily wear standard cutting tools (e.g., inserts, taps, router bits)?
I'm looking for a simple set-up which will readily wear a tool -- for example, fly cutting copper, or turning G-10.
I would use what was locally available at reasonable cost. I like lathes best. Chose one with high power to speed test. In the old days, people ran machines slowly to maximize tool life, thinking they were minimzing cost. Now, smart shops run at high speeds, as tool cost is not so significant compared to other costs.
4130 forged bar is a great material for testing. Mediocre machinability, good strength, some degree of hardness, not too expensive. But I think you could use plain carbon steel bar or pipe just as well. It probably requires about 2x more material for similar wear.
But what do you mean when you say hard to machine? I don't think you mean exotics that give nasty surface finish.
Be careful doing your test and controls. I would claim that tool temperature is a primary wear predictor. Hard to keep this consistent between tests, or even to measure it.
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