GOALI: Mitigating Chemical Wear in Diamond Cutting Tools Using Novel Cutting Fluid Additives

目标：使用新型切削液添加剂减轻金刚石切削工具的化学磨损

• 批准号: 1634895
• 负责人: Johnson Samuel
• 金额: $ 30万
• 依托单位: Rensselaer Polytechnic Institute
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2016
• 资助国家: 美国
• 起止时间: 2016-09-01 至 2020-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1634895&HistoricalAwards=false
• 关键词: GOALI; Mitigating; Chemical; Wear; Diamond

Diamond tools are ill-suited for machining ferrous alloys (e.g. steel) because of the iron-induced chemical wear of diamond. The wear mitigation techniques identified to-date have received limited industrial acceptance because they involve either extensive modifications to the machining process or compositional modifications to the ferrous alloys. This award supports fundamental research that enables the development of novel cutting fluid additives to mitigate chemical wear in diamond tools when machining ferrous alloys. The successful mitigation of this tool wear will extend the benefits of using diamond tools (namely, realizing aggressive machining conditions and generating mirror-finish surfaces) to ferrous alloys. These alloys are used widely by the multi-billion dollar manufacturing industry spanning key application sectors such as aerospace, defense, automotive, and biomedicine. Research results will also benefit the cutting fluids industry. The research objective is to understand the influence of 2D materials on the diamond tool wear mitigation efficacy when machining ferrous alloys using colloidal suspensions of the 2D materials. The candidate 2D materials include graphene, graphene oxide, hexagonal boron nitride, molybdenum disulfide, and tungsten disulfide. Upon synthesis, the geometry of the 2D materials will be characterized using scanning electron microscopy and atomic force microscopy, whereas their chemistry will be characterized using the X-ray diffraction technique. Single point diamond turning experiments will be conducted on cylindrical ferrous workpieces. The ferrous materials of interest include iron (99.99 % purity) and steel with varying carbon concentrations, since carbon content in the alloy is known to influence the chemical wear of diamond tools. The wear mitigation efficacy of the colloidal suspensions will be quantified by measuring the volumetric tool wear (using optical profilometry), cutting temperature/forces (using in-situ sensing), carbon diffusion into the workpiece (using X-ray photoelectron spectroscopy), and surface roughness (using optical profilometry).

由于铁引起的金刚石化学磨损，金刚石工具不适合加工铁合金（例如钢）。迄今为止确定的磨损缓解技术已获得有限的工业认可，因为它们涉及对加工工艺的广泛修改或对铁合金的成分修改。该奖项支持基础研究，使新型切削液添加剂的开发，以减轻加工铁合金时金刚石工具的化学磨损。这种工具磨损的成功缓解将扩大使用金刚石工具的好处（即，实现积极的加工条件和产生镜面光洁度表面），以铁合金。这些合金被数十亿美元的制造业广泛使用，涵盖航空航天、国防、汽车和生物医学等关键应用领域。研究结果也将有利于切削液行业。研究目的是了解使用2D材料的胶体悬浮液加工铁合金时，2D材料对金刚石工具磨损减轻功效的影响。候选2D材料包括石墨烯、氧化石墨烯、六方氮化硼、二硫化钼和二硫化钨。在合成时，将使用扫描电子显微镜和原子力显微镜来表征2D材料的几何形状，而它们的化学性质将使用X射线衍射技术来表征。对圆柱形铁工件进行单点金刚石车削实验。感兴趣的铁类材料包括铁（99.99%纯度）和具有不同碳浓度的钢，因为已知合金中的碳含量会影响金刚石工具的化学磨损。将通过测量体积工具磨损（使用光学轮廓测定法）、切削温度/力（使用原位传感）、碳扩散到工件中（使用X射线光电子能谱法）和表面粗糙度（使用光学轮廓测定法）来量化胶体悬浮液的磨损缓解功效。