Service life enhancing design of surfaces with adjusted metalworking fluids on the example of lubicated metallic friction systems

本研究项目的总体目标是开发一种方法，以改善润滑金属摩擦系统的零件性能，并结合适当的添加剂金属加工液进行精加工。在精加工过程中，零件表面应进行预处理，即使在进一步减小零件尺寸或增加工作量的情况下，也能确保足够水平的恒定摩擦系数。通过这种方式，可以达到实际的使用寿命。很明显，金属加工液中添加剂的化学作用对机器零件的摩擦学性能有着有益的影响。首先，需要进一步研究，以了解导致磨合行为改善的化学和/或物理机制，并通过加工期间的预处理提高使用寿命。在拟议的研究项目中，应系统地探索基本原理，这对于了解加工后最终表面完整性与操作条件下表面完整性之间的因果关系是必要的。因此，特别感兴趣的是精加工过程，摩擦学负载和不同的高分辨率表面分析方法的组合应用之间的相互作用。为了完整地描述这些相互作用，有必要清楚地了解工艺参数之间的关系，表面层的成分之前和之后的摩擦负载和摩擦磨损行为从加工过程开始，直到最终形成的摩擦表面层在工作条件下。在此基础上，从摩擦学角度优化的精加工工艺将被定义，并为未来的加工工艺设计制定指导方针。

The general objective of this research project is the development of a method to improve the performance of parts for lubricated metallic friction systems in combination with appropiatly additivated metalworking fluids for finishing processes. Within the finishing process the parts surface should be pre-conditioned in that way, that even at further reduction of part size or increased workload a constant friction coefficient at sufficient level is secured. By this, the actual state of service life should nevertheless be achieved.It is evident, that chemical effects of additives in metalworking fluids provide a beneficiary effect on the tribological behavior of machine parts. A need for further research is in the first place given with regards to the understanding of the chemical and/or physical mechanisms which cause an improvement of the running-in behavior and as a result an enhancement of service life by a pre-conditioning during machining. Within the proposed research project the fundamentals should be explored systematically, which is necessaryto understand the cause-and-effect relationships between the final surface integrity after machining and the surface integrity under operating conditions. Of particular interest is therefore the interaction between finishingprocess, tribological load and the combined application of different high resolution methods for surface analysis. For complete description of these interactions it is necessary to understand clearly the relationshipsbetween process parameters, composition of surface layer before and after tribological load and the friction and wear behavior from the beginning of the machining process until the final formation of tribological surface layers under work conditions. Based on this, finishing processes which are optimized from a tribological point of view will be defined and guidelines for future design of machining processes will be established.