Tribological Analysis of Several Coatings under Flood and Cryogenic Cooling Conditions
Source abstract
Abstract
The contact between the tool and the workpiece/chip in metal cutting is complex, resulting in high local temperatures and stresses, which may cause severe tool wear and failure. Developments in cryogenic-assisted machining have shown an ecological alternative to the classical metal working fluids, besides tool wear reduction during machining difficult-to-cut materials due to the good ability to dissipate the heat generated by this process. The objective of this work is to analyze the tribological conditions and performance of new coatings specially developed for cryogenic-assisted machining in terms of friction coefficient, volume of build-up material (adhesion) to the tool, and tool temperature. The results have shown that the sliding speed and cooling/lubrication strategy are two main factors that affect the friction coefficient and adhesion of Ti–6Al–4V alloy to the pins. These tribological tests should allow us to select the best coating(s) to be used in cutting tools for further tool wear analysis. Moreover, the obtained friction coefficients could be further implemented into metal cutting models to predict the machining outcomes, including the surface integrity of the machined parts and tool wear.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Metal Alloys Wear and Properties · Advanced machining processes and optimization · Advanced materials and composites
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
LABOMAP, Arts et Metiers Institute of Technology, Université Bourgogne Franche-Comté, HESAM Université, F-71250 Cluny, France
Department of Mechanical Engineering and Engineering Science, University of North Carolina at Charlotte, Charlotte, NC 28223, USA
Knowledge and Skills, F-71000 Macon, France
Funding
Chinese Scholarship Council
References (60)
Show source-provided references
1. Present Situation and Future Trends in Modelling of Machining Operations Progress Report of the CIRP Working Group ‘Modelling of Machining Operations’10.1016/S0007-8506(07)63244-2 ↗
2. Velocity effects in metal forming and machining processes10.1016/j.cirp.2011.05.001 ↗
3. Characterisation of friction and heat partition coefficients at the tool-work material interface in cutting10.1016/j.cirp.2013.03.099 ↗
4. A new experimental methodology to analyse the friction behaviour at the tool-chip interface in metal cutting10.1007/s11740-012-0386-6 ↗
5. Simulation of cutting tool wear by a modified pin-on-disc test10.1016/0890-6955(89)90007-2 ↗
6. Friction and wear testing of multilayer coatings on carbide substrates for dry machining applications10.1016/S0257-8972(02)00040-3 ↗
7. Innovative Methods for the Investigation of Tool-Chip Adhesion and Layer Formation during Machining10.1016/S0007-8506(07)60049-3 ↗
8. Observations of the tool–chip boundary conditions in turning of aluminum alloys10.1016/j.wear.2006.08.019 ↗
9. A new approach for the friction identification during machining through the use of finite element modelling10.1016/j.ijmachtools.2007.08.022 ↗
10. An Investigation of the Thermal Effects in Orthogonal Cutting Associated with Multilayer Coatings10.1016/S0007-8506(07)62069-1 ↗
11. Identification of a friction model at tool/chip/workpiece interfaces in dry machining of AISI4142 treated steels10.1016/j.jmatprotec.2008.09.019 ↗
12. Identification of a friction model—Application to the context of dry cutting of an AISI 1045 annealed steel with a TiN-coated carbide tool10.1016/j.triboint.2008.10.007 ↗
13. New tribometer designed for the characterisation of the friction properties at the tool/chip/workpiece interfaces in machining10.1002/tt.50 ↗
14. Ren, J., and Yuan, H. (2022). Contact Analysis and Friction Prediction of Non-Gaussian Random Surfaces. Appl. Sci., 12.10.3390/app122111237 ↗
15. Goel, S., Björklund, S., Curry, N., Govindarajan, S., Wiklund, U., Gaudiuso, C., and Joshi, S. (2020). Axial Plasma Spraying of Mixed Suspensions: A Case Study on Processing, Characteristics, and Tribological Behavior of Al2O3-YSZ Coatings. Appl. Sci., 10.10.3390/app10155140 ↗
16. Wu, N., Hu, N., Wu, J., and Zhou, G. (2020). Tribology Properties of Synthesized Multiscale Lamellar WS2 and Their Synergistic Effect with Anti-Wear Agent ZDDP. Appl. Sci., 10.10.3390/app10010115 ↗
17. Le, V.N.-A., and Lin, J.-W. (2017). Tribological Properties of Aluminum Nanoparticles as Additives in an Aqueous Glycerol Solution. Appl. Sci., 7.10.3390/app7010080 ↗
18. Preliminary Microstructural and Microscratch Results of Ni-Cr-Fe and Cr3C2-NiCr Coatings on Magnesium Substrate10.1088/1757-899X/209/1/012024 ↗
19. In-process measurement of friction coefficient in orthogonal cutting10.1016/j.cirp.2014.03.083 ↗
20. Identification of a friction model—Application to the context of dry cutting of an AISI 316L austenitic stainless steel with a TiN coated carbide tool10.1016/j.ijmachtools.2008.03.011 ↗
21. In-process Measurement of the Coefficient of Friction on Titanium10.1016/j.procir.2017.03.212 ↗
22. Tribological properties of polymers PI, PTFE and PEEK at cryogenic temperature in vacuum10.1016/j.cryogenics.2016.01.001 ↗
23. Friction and wear at low temperatures10.1016/S0360-3199(97)00070-0 ↗
24. Friction and wear behaviour of hard and superhard coatings at cryogenic temperatures10.1016/S0301-679X(01)00009-3 ↗
25. Low temperature investigations on frictional behaviour and wear resistance of solid lubricant coatings10.1016/S0301-679X(01)00013-5 ↗
26. Low temperature tribology at the B. Verkin Institute for Low Temperature Physics & Engineering (historical review)10.1016/S0301-679X(01)00010-X ↗
27. Modeling of cryogenic frictional behaviour of titanium alloys using Response Surface Methodology approach10.1016/j.matdes.2009.05.020 ↗
28. Basmaci, G., Yoruk, A.S., Koklu, U., and Morkavuk, S. (2017). Impact of Cryogenic Condition and Drill Diameter on Drilling Performance of CFRP. Appl. Sci., 7.10.3390/app7070667 ↗
29. The Influence of Cryogenic Coolants in Machining of Ti–6Al–4V10.1115/1.4024058 ↗
30. Gases are good cutting coolants
31. Thermo-Mechanical Tool Load during High Performance Cutting of Hard-to-Cut Materials10.1016/j.procir.2012.04.053 ↗
32. Experimental investigation on the feasibility of dry and cryogenic machining as sustainable strategies when turning Ti6Al4V produced by Additive Manufacturing10.1016/j.jclepro.2016.09.209 ↗
33. New observations on tool life, cutting forces and chip morphology in cryogenic machining Ti–6Al–4V10.1016/j.ijmachtools.2011.02.009 ↗
34. Understanding the tool wear mechanism during thermally assisted machining Ti–6Al–4V10.1016/j.ijmachtools.2012.07.001 ↗
35. On the tool wear mechanisms in dry and cryogenic turning Additive Manufactured titanium alloys10.1016/j.triboint.2016.09.034 ↗
36. Comparison of Ti6Al4V machining forces and tool life for cryogenic versus conventional cooling10.1177/0954405413486635 ↗
37. Effect of cryogenic compressed air on the evolution of cutting force and tool wear during machining of Ti–6Al–4V alloy10.1016/j.jmatprotec.2015.02.017 ↗
38. Tool wear in Ti-6Al-4V alloy turning under oils on water cooling comparing with cryogenic air mixed with minimal quantity lubrication10.1007/s00170-015-7062-x ↗
39. Cryogenic manufacturing processes10.1016/j.cirp.2016.06.007 ↗
40. A Review On Green Machining Techniques, Procedia Manufacturing10.1016/j.promfg.2020.10.241 ↗
41. The Use of Hybrid CO2+MQL in Machining Operations10.1016/j.proeng.2015.12.524 ↗
42. Tribological and thermal functions of cutting tool coatings10.1016/j.surfcoat.2003.11.027 ↗
43. The role of PVD coating and coolant nature in wear development and tool performance in cryogenic and wet milling of Ti–6Al–4V10.1016/j.wear.2017.02.049 ↗
44. Lequien, P. (2017). Fundamental Study of Cryogenic Assistance for Milling Application of Ti6Al4V. [Ph.D. Thesis, Ecole Nationale Supérieure d’Arts et Métiers—ENSAM]. Available online: https://pastel.archives-ouvertes.fr/tel-01743850.
45. Zhang, Y. (2022). Tool Materials Development for Improved Performance of Cutting Tools in Cryogenic Machining of Aeronautic Alloys. [Ph.D. Thesis, Ecole Nationale Supérieure d’Arts et Métiers—ENSAM]. Available online: https://www.theses.fr/2022HESAE009.
46. An explanation of the different regimes of friction and wear using asperity deformation models10.1016/0043-1648(79)90080-2 ↗
47. Zvorykin, K.A. (1896). On the force and energy necessary to separate the chip from the workpiece. Vetnik Promyslennostie., 123.
48. Modelling orthogonal cutting of Ti–6Al–4V titanium alloy using a constitutive model considering the state of stress10.1007/s00170-021-08446-9 ↗
49. Briscoe, B.J. (2006). Tribology of Metal Cutting, Elsevier. Tribology and Intergace Engineering Series, 52.
50. Evaluation of Present Numerical Models for Predicting Metal Cutting Performance and Residual Stresses10.1080/10910344.2015.1018537 ↗
51. Advances in material and friction data for modelling of metal machining10.1016/j.cirp.2017.05.002 ↗
52. A constitutive model for Ti6Al4V considering the state of stress and strain rate effects10.1016/j.mechmat.2019.103103 ↗
53. Propriétés du titane et de ses alliages
54. Materials science of cemented carbides—An overview10.1016/S0261-3069(01)00007-3 ↗
55. Yield stress of cemented tungsten carbide10.1063/1.321542 ↗
56. Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures10.1016/0013-7944(85)90052-9 ↗
57. Tribological behaviour of Ti6Al4V and Inconel718 under dry and cryogenic conditions—Application to the context of machining with carbide tools10.1016/j.triboint.2013.04.010 ↗
58. On the contact of elastic solids
59. Hills, D.A., Nowell, D., and Sackfield, A. (1998). Mechanics of Elastic Contacts, 1993, Butterworth-Heinemann.10.1016/B978-0-7506-0540-3.50013-1 ↗
60. Astakhov, V.P., and Joksch, S. (2012). Metalworking Fluids (MWFs) for Cutting and Grinding: Fundamentals and Recent Advances, Woodhead Publishing. [1st ed.].10.1533/9780857095305 ↗