nach oben

Erschienen in:

2021 | OriginalPaper | Buchkapitel

Tribology of Composite Materials and Coatings in Manufacturing

verfasst von : M. H. Sulaiman, N. A. Raof, A. N. Dahnel

Erschienen in: Tribological Applications of Composite Materials

Verlag: Springer Singapore

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config

KI-gestützte Suche

Aus

Abstract

The chapter presents studies regarding the tribological performance of composite materials and multilayer composite coated tools in manufacturing processes carried out by the authors. Two manufacturing processes were investigated—metal forming and metal cutting. In metal forming, the study aimed to explore lubricant-free forming utilizing multilayer DLC composite hard coating as the potential tool coating. The experimental studies on the coating include characterization of the coating, and tribological analysis of the coating using commercially available pin-on-disk, laboratory tribology simulative test and industrial ironing of stainless steel. In order to examine the influence of temperature and contact pressure along the tool/workpiece interface on friction, Finite Element analysis was performed. Meanwhile, in metal cutting, two environmentally benign machining techniques were investigated to determine their potentials in delaying tool wear progression. First, sustainable machining by coupling multilayer ceramic composite coated-tool with cryogenic coolant as the cutting fluid. Second, the machining of Carbon Fibre Composite and Titanium alloys stacks using Ultrasonic Assisted Drilling (UAD) technique. Both techniques include investigations on machining conditions with varied cutting tool speeds. The examinations on the experimental results were focused on temperature, tool wear, surface integrity and metallurgical structure of near-surface region.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Vorheriges Kapitel Effects of Lubrication on Tribological Properties of Composite MoS2-TiO2 Coating Material

Nächstes Kapitel Tribo-analysis of Polymer Composite in Spur Gear

Amiril SAS, Rahim EA, Syahrullail S (2017) A review on ionic liquids as sustainable lubricants in manufacturing and engineering: recent research, performance, and applications. J Clean Prod 168:1571–1589. https://doi.org/10.1016/j.jclepro.2017.03.197CrossRef

Azarhoushang B, Akbari J (2007) Ultrasonic-assisted drilling of Inconel 738-LC. Int J Mach Tools Manuf 47:1027–1033CrossRef

Babitsky V, Astashev V, Meadows A (2007) Vibration excitation and energy transfer during ultrasonically assisted drilling. J Sound Vib 308:805–814CrossRef

Barnes S (2013) Drilling performance of carbon fiber reinforced epoxy composite when machined dry, with conventional cutting fluid and with a cryogenically cooled tool. In: ASME 2013 international mechanical engineering congress and exposition, pp 1–10

Barnes S, Ascroft H (2015) Study of cutting forces and surface roughness in milling of carbon fibre composite (CFC) with conventional and pressurized CO₂ cutting fluids. In: Proceedings of the ASME 2015 international mechanical engineering congress and exposition, pp 1–8

Bay N (2013) New tribo-systems for cold forming of steel, stainless steel and aluminium alloys. In: Proceedings of 46th International Cold Forging Group (ICFG) plenary meeting, pp 7–04

Bermingham MJ, Kirsch J, Sun S, Palanisamy S, Dargusch MS (2011) New observations on tool life, cutting forces and chip morphology in cryogenic machining Ti-6Al-4V. Int J Mach Tools Manuf 51:500–511. https://doi.org/10.1016/j.ijmachtools.2011.02.009CrossRef

Biksa A, Yamamoto K, Dosbaeva G, Veldhuis SC, Fox-Rabinovich GS, Elfizy A, Wagg T, Shuster LS (2010) Wear behavior of adaptive nano-multilayered AlTiN/MexN PVD coatings during machining of aerospace alloys. Tribol Int 43:1491–1499. https://doi.org/10.1016/j.triboint.2010.02.008CrossRef

Ceron E, Bay N (2013) A methodology for off-line evaluation of new environmentally friendly tribo-systems for sheet metal forming. CIRP Ann Manuf Technol 62:231–234. https://doi.org/10.1016/j.cirp.2013.03.062CrossRef

Ceron E, Olsson M, Bay N (2014) Lubricant film breakdown and material pick-up in sheet forming of advanced high strength steels and stainless steels when using environmental friendly lubricants. Adv Mater Res 967:219–227. https://doi.org/10.4028/www.scientific.net/AMR.966-967.219CrossRef

Chang S, Bone G (2005) Burr size reduction in drilling by ultrasonic assistance. Robot Comput Integr Manuf 21:442–450CrossRef

Chuan P, Ghani JA, Jameelah M, Ria T (2013) Characterization of TiCN and TiCN/ZrN coatings for cutting tool application. Ceram Int 39:1293–1298CrossRef

Courbon C, Pusavec F, Dumont F, Rech J, Kopac J (2013) Tribological behaviour of Ti6Al4V and Inconel718 under dry and cryogenic conditions—application to the context of machining with carbide tools. Tribol Int 66:72–82. https://doi.org/10.1016/j.triboint.2013.04.010CrossRef

Dahnel AN (2017) Conventional and ultrasonic assisted drilling of carbon fibre reinforced polymer/titanium alloy stacks (Doctoral dissertation, University of Warwick)

Dahnel AN, Ascroft H, Barnes S, Gloger M (2015) Analysis of tool wear and hole quality during ultrasonic assisted drilling (UAD) of carbon fibre composite (CFC)/titanium alloy (Ti6Al4V) stacks. In: ASME 2015 international mechanical engineering congress and exposition, pp 1–10

Dahnel AN, Ascroft H, Barnes S (2016) The effect of varying cutting speeds on tool wear during conventional and ultrasonic assisted drilling (UAD) of carbon fibre composite (CFC) and titanium alloy stacks. Procedia CIRP 46:420–423. https://doi.org/10.1016/j.procir.2016.04.044CrossRef

de Neergaard A (2017) Personal communication with M.H. Sulaiman

Dhar NR, Paul S, Chattopadhyay AB (2001) The influence of cryogenic cooling on tool wear, dimensional accuracy and surface finish in turning AISI 1040 and E4340C steels. Wear 249:932–942. https://doi.org/10.1016/S0043-1648(01)00825-0CrossRef

Gassner M, Schalk N, Tkadletz M, Pohler M, Czettl C, Mitterer C (2018) Influence of cutting speed and workpiece material on the wear mechanisms of CVD TiCN/α-Al2O3 coated cutting inserts during turning. Wear 398–399:90–98CrossRef

Holmberg K, Laukkanen A, Ghabchi A, Rombouts M, Turunen E, Waudby R, Suhonen T, Valtonen K, Sarlin E (2014) Computational modelling based wear resistance analysis of thick composite coatings. Tribiology Int 72:13–30. https://doi.org/10.1016/j.triboint.2013.12.001CrossRef

Hong SY, Ding Y, Jeong W (2001a) Friction and cutting forces in cryogenic machining of Ti–6Al–4V. Int J Mach Tools Manuf 41:2271–2285. https://doi.org/10.1016/S0890-6955(01)00029-3CrossRef

Hong SY, Markus I, Jeong W (2001b) New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4V. Int J Mach Tools Manuf 41:2245–2260. https://doi.org/10.1016/S0890-6955(01)00041-4CrossRef

Hosseini A, Kishawy H (2014) Cutting tool materials and tool wear. In: Davim J (ed) Machining of titanium alloys. Springer, Berlin

Jawahir IS, Attia H, Biermann D, Duflou J, Klocke F, Meyer D, Newman ST, Pusavec F, Putz M, Rech J, Schulze V, Umbrello D (2016) Cryogenic manufacturing processes. CIRP Ann Manuf Technol 65:713–736. https://doi.org/10.1016/j.cirp.2016.06.007CrossRef

Kaynak Y (2014) Evaluation of machining performance in cryogenic machining of Inconel 718 and comparison with dry and MQL machining. Int J Adv Manuf Technol 72:919–933. https://doi.org/10.1007/s00170-014-5683-0CrossRef

Kaynak Y, Karaca HE, Jawahir IS (2011) Cryogenic machining of NiTi shape memory alloys. In: 6th international conference and exhibition on design and production of machines and dies/molds, pp 123–128

Kaynak Y, Karaca HE, Noebe RD, Jawahir IS (2013a) Analysis of tool-wear and cutting force components in dry, preheated, and cryogenic machining of NiTi shape memory alloys. Procedia CIRP 8:498–503. https://doi.org/10.1016/j.procir.2013.06.140CrossRef

Kaynak Y, Karaca HE, Noebe RD, Jawahir IS (2013b) Tool-wear analysis in cryogenic machining of NiTi shape memory alloys: a comparison of tool-wear performance with dry and MQL machining. Wear 306:51–63. https://doi.org/10.1016/j.wear.2013.05.011CrossRef

Kijima H, Bay N (2007) Contact conditions in skin-pass rolling. CIRP Ann Manuf Technol 56:301–306. https://doi.org/10.1016/j.cirp.2007.05.070CrossRef

Kim KS, Kim HK, La JH, Lee SY (2016) Effects of interlayer thickness and the substrate material on the adhesion properties of CrZrN coatings. Jpn J Appl Phys 55:01AA02. https://doi.org/10.7567/JJAP.55.01AA02

Li R, Shih A (2007) Tool temperature in titanium drilling. J Manuf Sci Eng 129:740–749CrossRef

Liu D, Tang Y, Cong W (2012) A review of mechanical drilling for composite laminates. Compos Struct 94:1265–1279CrossRef

Lukaszkowicz K (2011) Review of nanocomposite thin films and coatings deposited by PVD and CVD technology. Nanomaterials 145–162. https://doi.org/10.5772/25799

Makhdum F, Phadnis VA, Roy A, Silberschmidt VV (2014) Effect of ultrasonically assisted drilling on carbon fibre reinforced plastics. J Sound Vib 333:5939–5952CrossRef

Merklein M, Schmidt M, Wartzack S, Tremmel S, Andreas K, Häfner T, Zhao R, Steiner J (2015) Development and evaluation of tool sided surface modifications for dry deep drawing of steel and aluminum alloys. Dry Met Form Open Access J 1:121–133

More AS, Jiang W, Brown WD, Malshe AP (2006) Tool wear and machining performance of cBN–TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel. J Mater Process Technol 180:253–262. https://doi.org/10.1016/j.jmatprotec.2006.06.013CrossRef

Paul S, Chattopadhyay AB (1996) The effect of cryogenic cooling on grinding forces. Int J Mach Tools Manuf 36:63–72. https://doi.org/10.1016/0890-6955(95)92629-DCrossRef

Pecat O, Brinksmeier E (2014) Tool wear analyses in low frequency vibration assisted drilling of CFC/Ti6Al4V stack material. Procedia CIRP 14:142–147CrossRef

Pu Z (2012) Cryogenic machining and burnishing of AZ31B magnesium alloy for enhanced surface integrity and functional performance

Pušavec F, Govekar E, Kopač J, Jawahir IS (2011) The influence of cryogenic cooling on process stability in turning operations. CIRP Ann Manuf Technol 60:101–104. https://doi.org/10.1016/j.cirp.2011.03.096CrossRef

Raof NA, Ghani JA, Haron CHC (2019) Machining-induced grain refinement of AISI 4340 alloy steel under dry and cryogenic conditions. J Mater Res Technol 8:4347–4353CrossRef

Rotella G, Umbrello D, Dillon OW, Jawahir IS (2012) Evaluation of process performance for sustainable hard machining. J Adv Mech Des Syst Manuf 6:989–998CrossRef

Shokrani A, Dhokia V, Newman ST (2012) Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids. Int J Mach Tools Manuf 57:83–101. https://doi.org/10.1016/j.ijmachtools.2012.02.002CrossRef

Shokrani A, Dhokia V, Muñoz-Escalona P, Newman ST (2013) State-of-the-art cryogenic machining and processing. Int J Comput Integr Manuf 26:616–648. https://doi.org/10.1080/0951192X.2012.749531CrossRef

Shyha I, Soo S, Aspinwall D, Bradley S, Perry R, Harden P, Dawson S (2011) Hole quality assessment following drilling of metallic-composite stacks. Int J Mach Tools Manuf 51:569–578CrossRef

Strano M, Chiappini E, Tirelli S, Albertelli P, Monno M (2013) Comparison of Ti6Al4V machining forces and tool life for cryogenic versus conventional cooling. Proc Inst Mech Eng Part B J Eng Manuf 227:1403–1408. https://doi.org/10.1177/0954405413486635CrossRef

Sulaiman MH (2017) Development and testing of tailored tool surfaces for sheet metal forming

Sulaiman MH, Christiansen P, Bay N (2017a) A study of DLC coatings for ironing of stainless steel. In: 36th International Deep Drawing Research Group (IDDRG), pp 1–6

Sulaiman MH, Christiansen P, Bay N (2017b) A study of anti-seizure tool coatings for ironing of stainless steel. J Tribol Spec Issue WTC2017 17:1–11

Sulaiman MH, Farahana RN, Mustaffa MN, Bienk K (2019a) Tribological properties of DLC coating under lubricated and dry friction condition. IOP Conf Ser Mater Sci Eng 670:012052CrossRef

Sulaiman MH, Farahana RN, Bienk K, Nielsen CV, Bay N (2019b) Effects of DLC/TiAlN-coated die on friction and wear in sheet-metal forming under dry and oil-lubricated conditions: experimental and numerical studies. Wear 438–439:203040CrossRef

Syahrullail S, Zubil BM, Azwadi CSN, Ridzuan MJM (2011) Experimental evaluation of palm oil as lubricant in cold forward extrusion process. Int J Mech Sci 53:549–555. https://doi.org/10.1016/j.ijmecsci.2011.05.002CrossRef

Tool-life testing with single-point turning tools. STN ISO 3685 (1993)

Venugopal KA, Paul S, Chattopadhyay AB (2007) Growth of tool wear in turning of Ti-6Al-4V alloy under cryogenic cooling. Wear 262:1071–1078. https://doi.org/10.1016/j.wear.2006.11.010

Vereshchaka AA, Vereshchaka AS, Mgaloblishvili O, Morgan MN, Batako AD (2014) Nano-scale multilayered-composite coatings for the cutting tools. Int J Adv Manuf Technol 72:303–317. https://doi.org/10.1007/s00170-014-5673-2CrossRef

Wang Z, Rajurkar K (1997) Wear of CBN tool in turning of silicon nitride with cryogenic cooling. Int J Mach Tools Manuf 37:319–326CrossRef

Wang ZY, Rajurkar KP (2000) Cryogenic machining of hard-to-cut materials. Wear 239:168–175. https://doi.org/10.1016/S0043-1648(99)00361-0CrossRef

Wang MX, Zhang JJ, Yang J, Wang LQ, Li DJ (2007) Influence of Ar/N2 flow ratio on structure and properties of nanoscale ZrN/WN multilayered coatings. Surf Coatings Technol 201:5472–5476. https://doi.org/10.1016/j.surfcoat.2006.07.015CrossRef

Wang X, Kwon P, Sturtevant C, Kim D, Lantrip J (2014) Comparative tool wear study based on drilling experiments on CFRP/Ti stack and its individual layers. Wear 317:265–276CrossRef

Yasa E, Pilatin S, Çolak O (2012) Overview of cryogenic cooling in machining of Ti alloys and a case study. J Prod Eng 2:1–9

Yuan Z, Guo Y, Li C, Liu L, Yang B, Song H, Zhai Z, Lu Z, Li H, Staedler T, Huang N, Jiang X (2020) New multilayered diamond/β-SiC composite architectures for high-performance hard coating. Mater Des 186:108207CrossRef

Zulhanafi P, Syahrullail S (2019) The tribological performances of super olein as fluid lubricant using four-ball tribotester. Tribol Int 130:85–93. https://doi.org/10.1016/j.triboint.2018.09.013CrossRef

Titel: Tribology of Composite Materials and Coatings in Manufacturing
verfasst von: M. H. Sulaiman
N. A. Raof
A. N. Dahnel
Verlag: Springer Singapore
Buch: Tribological Applications of Composite Materials
Print ISBN: 978-981-15-9634-6

Electronic ISBN: 978-981-15-9635-3

Copyright-Jahr: 2021
DOI: https://doi.org/10.1007/978-981-15-9635-3_11

Premium Partner

Marktübersichten

Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.

Zur Marktübersicht