Mechanisms of Friction and Wear Reduction in Embedded Solid Lubricant Coatings and Their Application to Machining Processes

本研究项目的目的是研究新型嵌入式固体润滑剂刀具涂层在机械加工和制造过程中的应用。本研究的概念是利用平版制版方法制造双组分涂料。涂层的一个组成部分将是高度耐磨的硬质化合物，而嵌入在硬质化合物中的第二个组成部分将是固体润滑剂材料。这种方法将缓解固体润滑剂涂层在使用中遇到的一个常见问题，即磨损寿命短。该研究项目将研究这些涂层的制造方法和图案，涂层的机械和热稳定性，以及决定其摩擦行为的有效摩擦学机制。除了对涂层进行实验室分析和摩擦学测试外，研究的一个关键组成部分将是将涂层应用于切削工具并进行仪器化的金属切削测试。使用切割和成形工艺制造工程金属部件的能力是广泛制造工艺的组成部分。将涂层应用于刀具和金属成形模具，可以提高刀具寿命，减少克服摩擦力所消耗的能量。液体润滑剂的使用也减少了摩擦，但是，环境和健康问题，以及对其处理和处置费用的经济关切，使固体润滑剂的使用更具吸引力。该研究项目将促进含固体润滑剂的高耐磨涂层的发展。使用这些涂层可以减少环境废物，并降低废液处理和处置的成本。该计划还旨在通过开发可用于高中水平的便携式教育模块来提高对工程涂料的技术认识。

The objective of this research project is to investigate novel embedded solid lubricant cutting tool coatings for applications in machining and manufacturing processes. The research concept is to use lithographic patterning methods to create two-component coatings. One component of the coating will be a hard compound that is highly wear resistant, and the second component, embedded in the hard compound, will be a solid lubricant material. This approach will alleviate a common problem encountered in the use of solid lubricant coatings, namely short wear life. This research project will investigate methods for fabricating and patterning these coatings, the mechanical and thermal stability of the coatings, and the operative tribological mechanisms that determine their frictional behavior. In addition to laboratory analysis and tribological testing of the coatings, a key component of the research will be to apply the coatings to cutting tools and perform instrumented metal cutting tests.The ability to fabricate engineered metallic components using cutting and forming processes is integral to a wide range of manufacturing processes. The application of coatings to cutting tools and metal forming dies can enhance tool life and reduce the energy expended in overcoming frictional forces. The use of liquid lubricants also reduces friction, however, environmental and health issues, as well as economic concern over the cost of their treatment and disposal has made the use of solid lubricants more attractive. This research program will promote the development of high wear-resistance coatings incorporating solid lubricants. The use of these coatings could lead to a reduction in environmental waste, as well as reducing the costs of waste fluid treatment and disposal. The program also aims to improve technical awareness about engineered coatings by developing portable educational modules that can be used at the high-school level.