Investigation on the Wear Behavior of Coatings for Lubricant-Free Deep Drawing Processes with a Novel Application-Oriented Test Rig

2020 ◽  
Vol 404 ◽  
pp. 11-18
Author(s):  
Johannes Henneberg ◽  
Marion Merklein
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Deep Drawing ◽  
Wear Behavior ◽  
Wear Test ◽  
Lubricant Layer ◽  
Efficient Production ◽  
Test Rig ◽  
Drawing Die ◽  
Lubricant Application

Lubricant-free deep drawing is motivated by the avoidance of using environmentally harmful lubricants as well as the potential for shortening the process chain by eliminating lubricant application and component cleaning. Central challenges of dry deep drawing are a significant increase in friction as well as in adhesive tool wear due to a lack of a separating lubricant layer between tool and workpiece. An approach to meet these challenges is the modification of the tools through diamond-like coatings. Based on findings from laboratory tests, a-C:H and ta-C coatings were selected and their effectiveness in overcoming these challenges was demonstrated in single stroke tests in previous research. In order to use the process-specific advantages of forming technology, high tool life is required. In this context, this research aims at investigating the application behavior of a-C:H and ta-C coatings during lubricant-free deep drawing of a high number of components made of the aluminum alloy AA5182. For this purpose, a new wear test rig is applied, which enables the time and material efficient production of high quantities. Numerical methods are utilized to identify the drawing die radius as well as the blank holder as the highest loaded areas. Based on these findings, the wear of the coatings as well as that of an uncoated tool as a reference is analyzed in these areas by optical and tactile measurements. In addition, the influence of tool wear on the component surface quality is determined. It is proven that the ta-C coating increases the tool life from 10 components in uncoated condition up to 3,000 components.

Tool Wear Mechanisms in High Speed Machining Ductile Cast Iron

2010 ◽  
Vol 29-32 ◽  
pp. 1527-1531
Author(s):  
Fa Zhan Yang ◽  
Jian Qiang Zhou ◽  
Guang Yao Meng ◽  
Jun Zhao ◽  
Chang He Li
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Wear Behavior ◽  
Orthogonal Cutting ◽  
Ductile Cast Iron ◽  
Cemented Carbide ◽  
Rake Face ◽  
High Speed Cutting

Wear behavior of WC based nanocomposite cutting tool when high speed cutting ductile cast iron was investigated. Orthogonal cutting tests were carried out on a CA6140 lathe using three speeds, namely, 100, 215 and 287m min-1. The WC based nanocomposite tool is found to be superior to cemented carbide tools (YG8). The tool life is prolonged 60% as compared to cemented carbide, as the width of the wear land (VB), which was monitored at selected time intervals. Meanwhile, the topography of worn surfaces was scanned by a profilemeter. Wear characterization of the rake face and the flank surfaces as well as of the collected chips was conducted using a scanning electron microscopy (SEM). Results showed that distinctive traces of single abrasive tool wear event were found on the rake face of the tool, additionally, the adhesion wear is the main wear mechanism in the flank face of the tool. However, the extent of improvement in tool life depends strongly on the cutting conditions, with the greatest benefits being seen at higher cutting speeds and feed rates.

Effect of Reinforcement and Chills on the Tribological Behaviour of Al-12% Si/B4C Composite

2008 ◽  
Author(s):  
G. R. Bharath Sai Kumar ◽  
S. Gopal Prakash
Keyword(s):  
Wear Behavior ◽  
Wear Test ◽  
Dry Sliding ◽  
Test Rig ◽  
Tribological Behaviour ◽  
The Matrix ◽  
B4c Particles ◽  
Pin On Disk ◽  
Boron Carbide B4c ◽  
Test Result

Effect of reinforcement on the wear behavior of Aluminium-12%Si(LM6) reinforced with Boron Carbide (B4C) particles (quantity from 3 to 12 wt% in steps of 3 wt%; size 40–80μm) was investigated by a computerized pin-on-disk wear test rig under dry sliding conditions. Mild steel chill was used. Castings were prepared using dry sand moulds and the reinforcement particles were introduced into the matrix using Vortex-Route Method. Test result showed that this MMC was greatly influenced by the reinforcement and chill. It was found that 9 wt% of B4C particles in Aluminium-12%Si (LM6) alloy exhibited the least wear rate. An attempt to evaluate the tribological properties of this MMC with respect to reinforcement, chill and microstructure is made.

TiN Modified Layer on the 20CrNiMo Steel Surface by Needle–Shape Cathode Glow Plasma Discharging

2011 ◽  
Vol 306-307 ◽  
pp. 553-556
Author(s):  
Fei Chen ◽  
Jia Qing Chen ◽  
Hai Zhou
Keyword(s):  
Friction Coefficient ◽  
High Speed ◽  
Friction And Wear ◽  
Wear Behavior ◽  
Wear Test ◽  
Dry Sliding ◽  
Test Rig ◽  
Modified Layer ◽  
Glow Plasma ◽  
Testing Condition

The structure made of alloying and coating layers of TiN was achieved on the surface of 20CrNiMo steel by the needle-shape cathode glow discharging. It is aimed to reduce the friction coefficient of the 20CrNiMo and to improve the property of the wear-resistance. The morphology of TiN modified layer at cross section was observed by the scanning electron microscope (SEM). The friction and wear behavior of the TiN layer under dry sliding against GCr15 steel was evaluated on a MFT-4000 high speed to-and-fro wear test rig. The results showed that it was feasible to prepare TiN modified layer of 40μm thickness by the needle-shape cathode glow plasma discharging. It has been found that the TiN modified layer has excellent friction and wear-resistant behaviors. The friction coefficient of the 20CrNiMo substrate was about 0.324 under dry sliding, while the TiN modified layer experienced much abated friction coefficient to 0.169 under the same testing condition.

scholarly journals Investigation of the Wear Behavior of PVD Coated Carbide Tools during Ti6Al4V Machining with Intensive Built Up Edge Formation

Coatings ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 266
Author(s):  
M.S.I. Chowdhury ◽  
B. Bose ◽  
S. Rawal ◽  
G.S. Fox-Rabinovich ◽  
S.C. Veldhuis
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Wear Behavior ◽  
Cutting Temperature ◽  
Ti6al4v Alloy ◽  
Adhesive Interaction ◽  
Heavy Load ◽  
Micromechanical Properties ◽  
Rough Turning ◽  
Coated Carbide

Tool wear phenomena during the machining of titanium alloys are very complex. Severe adhesive interaction at the tool chip interface, especially at low cutting speeds, leads to intensive Built Up Edge (BUE) formation. Additionally, a high cutting temperature causes rapid wear in the carbide inserts due to the low thermal conductivity of titanium alloys. The current research studies the effect of AlTiN and CrN PVD coatings deposited on cutting tools during the rough turning of a Ti6Al4V alloy with severe BUE formation. Tool wear characteristics were evaluated in detail using a Scanning Electron Microscope (SEM) and volumetric wear measurements. Chip morphology analysis was conducted to assess the in situ tribological performance of the coatings. A high temperature–heavy load tribometer that mimics machining conditions was used to analyze the frictional behavior of the coatings. The micromechanical properties of the coatings were also investigated to gain a better understanding of the coating performance. It was demonstrated that the CrN coating possess unique micromechanical properties and tribological adaptive characteristics that minimize BUE formation and significantly improve tool performance during the machining of the Ti6Al4V alloy.

scholarly journals Machining of Titanium Metal Matrix Composites: Progress Overview

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5011
Author(s):  
Cécile Escaich ◽  
Zhongde Shi ◽  
Luc Baron ◽  
Marek Balazinski
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Metal Matrix ◽  
Dust Emission ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Titanium Metal ◽  
Machining Processes ◽  
Tool Wear Mechanisms

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).

Evaluation of Cooling Potential and Tool Life in Turning Using Metalworking Fluids Delivered in Supercritical Carbon Dioxide

2009 ◽  
Author(s):  
Andres F. Clarens ◽  
Ye-Eun Park ◽  
Jacob Temme ◽  
Kim Hayes ◽  
Fu Zhao ◽  
...  
Keyword(s):  
Carbon Dioxide ◽  
Tool Wear ◽  
Tool Life ◽  
Heat Removal ◽  
Minimum Quantity Lubrication ◽  
Metalworking Fluids ◽  
Compacted Graphite ◽  
Lower Viscosity ◽  
Cutting Zone ◽  
Machining Operations

Carbon Dioxide is an industrial byproduct that has been proposed as an alternative metalworking fluid (MWF) carrier with lower environmental impacts and better cooling potential than existing MWFs. This paper investigates the heat removal and tool life effects of rapidly expanding supercritical CO2 (scCO2)-based MWFs relative to MWFs delivered as a flood of semi-synthetic emulsion or as minimum quantity lubrication (MQL) sprays. When cutting both compacted graphite iron (CGI) and titanium, tool wear was most effectively controlled using the scCO2-based MWF compared with the other MWFs. Analysis in this paper suggests that the performance benefit imparted by rapidly expanding scCO2 appears to be related to both the cooling potential and penetration of the sprays into the cutting zone. High-pressure gas sprays have lower viscosity and higher velocity than conventional MWFs. An experiment in which the spray direction was varied clearly demonstrated the importance of spray penetration in tool wear suppression. The type of gas spray is also a significant factor in tool wear suppression. For instance, a spray of N2 delivered under similar conditions to CO2 effectively reduced tool wear relative to water based fluids, but not as much as CO2. This result is particularly relevant for MQL sprays which are shown to not cool nearly as effectively as scCO2 MWFs. These results inform development of scCO2-based MWFs in other machining operations, and provide insight into the optimization of scCO2 MWF delivery.

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

Abrasive wear response of cryotreated EN45 steel in simulated wear test rig fixture

2015 ◽  
Vol 9 (3) ◽  
pp. 159-164 ◽  
Author(s):  
N. B. Dhokey ◽  
A. Raskar ◽  
A. R. Hake ◽  
G. Mohapatra
Keyword(s):  
Abrasive Wear ◽  
Wear Test ◽  
Test Rig ◽  
Wear Response

Tribological Properties of PTFE Nanocomposites Filled with Alumina Nanoparticles

2012 ◽  
Vol 557-559 ◽  
pp. 534-537 ◽  
Author(s):  
Yong Ping Niu ◽  
Sa Li ◽  
Jun Kai Zhang ◽  
Li Hua Cai ◽  
Yong Zhen Zhang
Keyword(s):  
Wear Resistance ◽  
Electron Microscope ◽  
Scanning Electron Microscope ◽  
Tribological Properties ◽  
Wear Behavior ◽  
Alumina Nanoparticles ◽  
Test Rig ◽  
Scanning Electron ◽  
Worn Surfaces

Polytetrafluoroethylene (PTFE) nanocomposites filled with alumina nanoparticles were prepared by compression molding and follow-up sintering. The tribological behaviors of PTFE nanocomposites sliding against GCr15 steel were evaluated using ball-on-disk tribology test rig. The worn surfaces of the unfilled and filled PTFE nanocomposite were investigated using a scanning electron microscope (SEM). The wear behavior of the PTFE nanocomposites was explained in terms of the topography of worn surfaces. It was found that the addition of alumina nanoparticles was effective in enhancing the wear resistance of the PTFE nanocomposite.

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