Promoting and Sustaining an Adaptive Response in Tool Materials

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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.