Promoting and Sustaining an Adaptive Response in Tool Materials

我的研究小组的总体目标是快速开发定制模具和调整工艺参数，以满足特定的工件和制造工艺要求。通过先进的模具表面工程，制造工艺性能得到了显著改善。迄今为止所采取的方法基本上是静态的，通常认为在沉积期间锁定了属性。我们的方法是动态的，利用切削工具表面的自然适应性反应，在极端摩擦下进行自我组织。 通过这种机制，在摩擦区形成有益的保护和润滑摩擦膜。这种效果类似于在一个人的手上形成老茧，以防止将来在艰苦工作中受伤。 我之前的发现奖发现了在机械加工应用中发挥有益功能的摩擦膜。我们证明了通过涂层成分、微观结构控制和调整加工工艺条件来影响其形成的能力。我们现在正在与我们的行业合作伙伴将这些成果商业化，并在其运营中实现显着的性能改进。 为了进一步提高我们的知识，我的团队现在正在密切结合表征和分析，包括建模，纳米压痕，划痕和摩擦测试，通过在我们的实验室数控机床上进行工业规模测试获得的实验结果以及随后的深入磨损表征。 本提案中描述的研究计划将有助于形成我们对自组织知识的基础，并使我们能够提高对如何在特定制造过程中促进和维持适应性反应的基本理解。 预期的发现包括： 1.识别用于加工难切削材料的有益摩擦膜，并将这些信息组织成功能性表面处理，主要集中在物理气相沉积（PVD）涂层上; 2.新型PVD涂层，可促进和维持第一项活动中确定的加工过程中的自适应反应; 3.工具特征和工艺条件，其增强并充分利用在前两个领域中识别和开发的自适应表面的独特性质。 结果将被组织成： 1.用于特定工具和工件材料的摩擦膜材料的数据库，其考虑了与温度和负载相关的局部处理条件; 2.涉及PVD涂层组合物和涂层工艺参数以及预表面处理和后表面处理的表面处理配方; 3.一种设计工具和调整工艺参数的方法，可进一步促进和维持随时间的适应性反应。 实现一个系统的方法，工具设计和工艺调整的基础上，一个表面的适应性反应的基本理解将提供加拿大制造商具有显着的竞争优势。

The overall objective of my research group is to rapidly develop custom tooling and tune process parameters to meet specific workpiece and manufacturing process requirements. Significant improvements in manufacturing process performance have been achieved through advanced surface engineering of tooling. The approach taken to date is largely static, with properties typically deemed locked in during deposition. Our approach is dynamic, leveraging the natural adaptive response on a cutting tool's surface to self-organize under extreme friction. Through this mechanism beneficial protective and lubricating tribofilms are formed in the friction zone. This effect is similar to how callouses form on one's hand to provide protection against future injury during hard work. My previous Discovery grant identified tribofilms that serve a beneficial function in machining applications. We demonstrated the ability to influence their formation through coating composition, microstructure control and by adjusting the machining process conditions. We are now commercializing these results with our industry partners and realizing significant performance improvements in their operations. To further advance our knowledge, my group is now closely integrating characterisation and analysis, including modeling, nano-indentation, scratch and tribometer testing, with experimental results gained through industry-scale testing on our lab CNC machines and subsequent in-depth characterisation of wear. The research program described in this proposal will help form the foundation of our knowledge on self-organization and allow us to improve our fundamental understanding of how to promote and sustain an adaptive response in a specific manufacturing process. Expected discoveries include: 1. the identification of beneficial tribofilms for the machining of difficult to cut materials and the organization of this information into functional surface treatments largely focusing on physical vapour deposited (PVD) coatings; 2. novel PVD coatings which promote and sustain the adaptive response during machining identified in the first activity; 3. tool features and process conditions which enhance and fully utilize the unique properties of adaptive surfaces identified and developed in the two previous areas. The results will be organized into: 1. a database of tribofilm materials for specific tool and workpiece materials factoring in local processing conditions related to temperature and load; 2. surface treatment formulations involving PVD coating composition and coating process parameters together with pre and post surface treatments; 3. a methodology for designing tools and tuning process parameters which further promote and sustain the adaptive response over time. Realizing a systematic approach to tool design and process tuning based on a fundamental understanding of the adaptive response of a surface will provide Canadian manufacturers with a significant competitive advantage.