Dry Cutting - New Coating Concepts for 2010

该基金为开发一种概念提供资金，通过利用切削刀具-工件界面上天然存在的氧化物来减少切削过程中的摩擦和热量，从而减少对冷却剂和润滑剂的需求，从而改进干式金属切削。刀具/工件相互作用的自然反应产物是一种或多种金属氧化物。设计一种工具涂层，当工具尖端达到一定温度时，它会产生自己的氧化色，这是合乎逻辑的，而不是违背自然。已经提出了涂层的组成和结构，这些将通过不平衡磁控反应溅射沉积进行探索。纳米层和分散相结构将以保持高温强度的思路进行研究，同时控制有色氧化物的形成速度。应选择在适当温度下产生氧化物并提供切削功能所需的固有强度的组合物。结构和成分将被充分表征，并与性能的相关性将通过提供切削温度、力和工件表面光洁度信息的仪器切削试验来确定。如果这个项目成功，它将为干切削刀具涂层设计的新策略的发展提供基础。它将为成功的加工技术的发展提供见解，以创造所需的涂层结构和纳入所需的氧化物形成元素。它将提供关于氧化物形成的控制和这些氧化物的行为的基本数据，因为它们影响切割行为。在实践中，成功的成果将有助于减少冷却液和润滑液的使用，这将对制造成本和工作场所的环境质量产生有利影响。

This grant provides funding for development of a concept to improve dry metal cutting by utilizing naturally occurring oxides at the cutting tool-work piece interface to reduce friction and heat due to the cutting process, thereby reducing the need for coolant and lubricant fluids. The natural reaction product of the cutting-tool/work-piece interaction is one or more metal oxide. It is logical to work with, rather than against nature by designing a tool coating that produces its own lubricious oxide when the tool tip reaches a certain temperature. Coating compositions and structures have been proposed and these will be explored by unbalanced magnetron reactive sputter deposition. Nano-layer and dispersed-phase structures will be investigated with the idea of retaining high temperature strength, while controlling the rate of lubricious oxide formation. Compositions will be chosen that produce oxides at appropriate temperatures and that provide the inherent strength required for the cutting function. The structures and compositions will be fully characterized and correlation with performance will be made using instrumented cutting tests that provide information on cutting temperature, force, and work-piece surface finish. If this project is successful, it will provide the foundation for the development of a new strategy in the design of dry-cutting tool coatings. It will provide insights to the development of successful processing techniques for the creation of the desired coating structures and for the incorporation of the desired oxide forming elements. It will provide fundamental data about the control of oxide formation and the behavior of such oxides as they impact cutting behavior. In practice, successful outcomes will contribute to a reduction in the use of cooling and lubricant fluids, which will favorably impact manufacturing costs and environmental quality in the work place.