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

这项研究项目的总体目标是开发一种方法，以提高润滑金属摩擦系统零件的性能，并结合适当添加的金属加工液进行精加工。在精加工过程中，零件表面应该以这种方式进行预处理，以便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。显然，金属加工液中添加剂的化学效应对机械零件的摩擦学行为是有利的。首先，需要对引起磨合行为改善的化学和/或物理机制进行进一步的研究，从而通过在加工过程中进行预调节来提高使用寿命。在拟议的研究项目中，应系统地探索基本原理，这是理解加工后的最终表面完整性与运行条件下的表面完整性之间的因果关系所必需的。因此，特别令人感兴趣的是抛光工艺、摩擦学载荷和不同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，必须清楚地了解工艺参数、摩擦学载荷前后的表面层成分与摩擦磨损行为之间的关系，从加工过程开始到工作条件下摩擦学表面层的最终形成。在此基础上，定义了从摩擦学角度优化的精加工工艺，并为今后的加工工艺设计制定了指导方针。

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.