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工具并调整工艺参数，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技术，制造工艺性能得到了显著改善。到目前为止采取的方法基本上是静态的，财产通常被认为在沉积期间被锁定。我们的方法是动态的，利用刀具表面的自然适应反应在极端摩擦下自组织。通过这种机制，在摩擦区形成了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，以防止在艰苦的工作中受到未来的伤害。 我之前的发现奖确定了摩擦膜在机械加工应用中具有有益的功能。我们展示了通过涂层成分、显微组织控制和调整加工工艺条件来影响它们的形成的能力。我们现在正在与我们的行业合作伙伴一起将这些成果商业化，并在他们的运营中实现显著的绩效改进。 为了进一步提高我们的知识，我的团队现在正在将表征和分析紧密地结合在一起，包括建模、纳米压痕、划痕和摩擦试验机测试，以及通过在我们的实验室数控机床上进行行业规模测试以及随后对磨损进行深入表征而获得的实验结果。 本提案中描述的研究计划将有助于形成我们关于自组织知识的基础，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响应的基本理解。 预期的发现包括： 1.确定用于加工难切割材料的有益摩擦膜，并将这些信息组织成主要侧重于物理气相沉积(PVD)涂层的功能性表面处理； 2.新的PVD涂层，促进和维持第一活动中确定的加工过程中的适应性响应； 3.增强和充分利用在前两个领域中确定和开发的自适应表面的独特性质的工具特征和工艺条件。 结果将被组织成： 1.考虑到与温度和载荷有关的本地加工条件，建立了特定刀具和工件材料的摩擦膜材料数据库； 2.表面处理配方，包括PVD涂层成分和涂层工艺参数以及前后的表面处理； 3.设计工具和调整工艺参数的方法，以便随着时间的推移进一步促进和维持适应性反应。 基于对表面自适应响应的基本了解，实现工具设计和工艺调整的系统方法将为加拿大制造商提供显著的竞争优势。

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.