Dry Cutting - New Coating Concepts for 2010

这笔赠款用于开发一种概念，通过利用刀具-工件界面上自然生成的氧化物来减少切割过程中产生的摩擦和热量，从而减少对冷却剂和润滑液的需求，从而改进干式金属切割。刀具/工件相互作用的自然反应产物是一种或多种金属氧化物。这是合乎逻辑的，而不是通过设计一种工具涂层来顺应自然，当工具尖端达到一定温度时，它会产生自己的有色氧化物。已经提出了涂层的组成和结构，并将通过非平衡磁控反应溅射沉积进行探索。将研究纳米层和分散相结构，以保持高温强度，同时控制有色氧化物的形成速度。将选择在适当的温度下产生氧化物并提供切割功能所需的固有强度的成分。结构和成分将得到充分表征，并将使用提供有关切割温度、力和工件表面光洁度信息的仪表化切割试验与性能进行关联。如果该项目成功，将为开发干切削刀具涂层设计的新战略奠定基础。它将为开发成功的加工技术，以产生所需的涂层结构和纳入所需的氧化物形成元素提供见解。它将提供关于氧化物形成的控制和此类氧化物在影响切割行为时的行为的基本数据。在实践中，成功的结果将有助于减少冷却和润滑液的使用，这将有利地影响工作场所的制造成本和环境质量。

This grant provides funding for development of a concept to improve dry metal cutting by utilizing naturally occurring oxides at the cutting tool-work piece interface to reduce friction and heat due to the cutting process, thereby reducing the need for coolant and lubricant fluids. The natural reaction product of the cutting-tool/work-piece interaction is one or more metal oxide. It is logical to work with, rather than against nature by designing a tool coating that produces its own lubricious oxide when the tool tip reaches a certain temperature. Coating compositions and structures have been proposed and these will be explored by unbalanced magnetron reactive sputter deposition. Nano-layer and dispersed-phase structures will be investigated with the idea of retaining high temperature strength, while controlling the rate of lubricious oxide formation. Compositions will be chosen that produce oxides at appropriate temperatures and that provide the inherent strength required for the cutting function. The structures and compositions will be fully characterized and correlation with performance will be made using instrumented cutting tests that provide information on cutting temperature, force, and work-piece surface finish. If this project is successful, it will provide the foundation for the development of a new strategy in the design of dry-cutting tool coatings. It will provide insights to the development of successful processing techniques for the creation of the desired coating structures and for the incorporation of the desired oxide forming elements. It will provide fundamental data about the control of oxide formation and the behavior of such oxides as they impact cutting behavior. In practice, successful outcomes will contribute to a reduction in the use of cooling and lubricant fluids, which will favorably impact manufacturing costs and environmental quality in the work place.