Catalytic Chemical Wear of Diamond Tools while Cutting Alloys

该奖项的研究目标是应用量子化学技术来预测不同成分合金的单点金刚石车削中使用的刀具的催化化学磨损率，然后验证这些预测。目前的理论成功地预测金刚石磨损率的元素金属，原子电子结构的基础上，但预测不适用于合金。 基于合金的电子结构，使用原子轨道的线性组合在金属和合金中形成分子轨道的方法，将生成用于预测切割合金时金刚石磨损的度量。一系列合金的磨损率将使用一种新的干涉测量技术来确定，并与新的度量标准进行比较。化学反应速率取决于局部温度，而局部温度又取决于材料特性和刀具边缘状况（磨损）。 切削温度将使用一种新的高温测量方法进行测量，切削力将使用测力计进行测量。这些数据将被用于标准化磨损率。如果成功的话，这项工作将提供一种选择最佳合金成分的方法，用于快速新兴的技术，如复杂薄膜的卷对卷生产或用于大批量光电产品的下一代光学模具。目前昂贵且耗时的每种合金成分的刀具磨损测试将被消除。此外，研究结果将激发研究界不同领域的新思维。提出的实验技术将是有用的精密加工研究的其他领域。 对合金催化活性的思考的变革可能会影响从金刚石合成到煤炭气化的各个领域。它还建议开发具有针对结构和催化行为优化的性能的合金。

The research objective of this award is to apply techniques from quantum chemistry to predict the catalyzed chemical wear rate of tools used in single point diamond turning of alloys with varying composition, and then to validate those predictions. Current theory successfully predicts diamond wear rates for elemental metals, based on atomic electronic structures, but the predictions do not apply to alloys. A metric for predicting diamond wear when cutting alloys will be generated based on the electronic structure of alloys, using a method with linear combinations of atomic orbitals to form molecular orbitals in metals and alloys. Wear rates for a range of alloys will be determined using a novel interferometric technique and compared with the new metric. Chemical reaction rates depend on local temperature, which depends on material properties and tool edge condition (wear). Cutting temperatures will be measured using a novel pyrometric method and cutting forces will be measured using a dynamometer. These data will be used to normalize wear rates.If successful, this work will provide a method of selecting optimum alloy compositions for such rapidly emerging technologies as roll-to-roll production of complex films or next generation optical molds for high volume optoelectronic products. The currently expensive, and time consuming, testing of tool wear for every alloy composition will be eliminated. In addition, the results will stimulate new thinking across diverse parts of the research community. The proposed experimental techniques will be useful in other areas of precision machining research. The transformative change in thinking about catalytic activity in alloys may impact areas ranging from diamond synthesis to coal gasification. It also suggests developing alloys with properties optimized for structural as well as catalytic behaviors.