GOALI: Mitigating Chemical Wear in Diamond Cutting Tools Using Novel Cutting Fluid Additives

金刚石工具不适合加工铁合金（如钢），因为铁会引起金刚石的化学磨损。迄今为止确定的减少磨损技术在工业上的接受程度有限，因为它们要么涉及对加工工艺的大量修改，要么涉及对铁合金的成分进行修改。该奖项支持基础研究，以开发新型切削液添加剂，以减轻加工铁合金时金刚石工具的化学磨损。成功减少这种刀具磨损将使使用金刚石刀具的优势（即实现激进的加工条件和产生镜面光洁度表面）扩展到铁合金。这些合金广泛应用于价值数十亿美元的制造业，包括航空航天、国防、汽车和生物医药等关键应用领域。研究成果也将有利于切削液行业。研究目的是了解利用二维材料的胶体悬浮液加工铁合金时，二维材料对金刚石刀具磨损减缓效果的影响。候选二维材料包括石墨烯、氧化石墨烯、六方氮化硼、二硫化钼和二硫化钨。合成后，二维材料的几何形状将使用扫描电子显微镜和原子力显微镜进行表征，而它们的化学性质将使用x射线衍射技术进行表征。单点金刚石车削实验将在圆柱形黑色金属工件上进行。我们感兴趣的含铁材料包括纯度为99.99%的铁和不同碳浓度的钢，因为已知合金中的碳含量会影响金刚石工具的化学磨损。胶体悬浮液的磨损缓解效果将通过测量刀具的体积磨损（使用光学轮廓法）、切削温度/力（使用原位传感）、碳扩散到工件（使用x射线光电子能谱）和表面粗糙度（使用光学轮廓法）来量化。

Diamond tools are ill-suited for machining ferrous alloys (e.g. steel) because of the iron-induced chemical wear of diamond. The wear mitigation techniques identified to-date have received limited industrial acceptance because they involve either extensive modifications to the machining process or compositional modifications to the ferrous alloys. This award supports fundamental research that enables the development of novel cutting fluid additives to mitigate chemical wear in diamond tools when machining ferrous alloys. The successful mitigation of this tool wear will extend the benefits of using diamond tools (namely, realizing aggressive machining conditions and generating mirror-finish surfaces) to ferrous alloys. These alloys are used widely by the multi-billion dollar manufacturing industry spanning key application sectors such as aerospace, defense, automotive, and biomedicine. Research results will also benefit the cutting fluids industry. The research objective is to understand the influence of 2D materials on the diamond tool wear mitigation efficacy when machining ferrous alloys using colloidal suspensions of the 2D materials. The candidate 2D materials include graphene, graphene oxide, hexagonal boron nitride, molybdenum disulfide, and tungsten disulfide. Upon synthesis, the geometry of the 2D materials will be characterized using scanning electron microscopy and atomic force microscopy, whereas their chemistry will be characterized using the X-ray diffraction technique. Single point diamond turning experiments will be conducted on cylindrical ferrous workpieces. The ferrous materials of interest include iron (99.99 % purity) and steel with varying carbon concentrations, since carbon content in the alloy is known to influence the chemical wear of diamond tools. The wear mitigation efficacy of the colloidal suspensions will be quantified by measuring the volumetric tool wear (using optical profilometry), cutting temperature/forces (using in-situ sensing), carbon diffusion into the workpiece (using X-ray photoelectron spectroscopy), and surface roughness (using optical profilometry).