International Journal of Machine Tools & Manufacture最新文献

{"title":"Laser-guided anisotropic etching for precision machining of micro-engineered glass components","authors":"Jun Li ,&nbsp;Shuai Zhong ,&nbsp;Jiaxu Huang ,&nbsp;Pei Qiu ,&nbsp;Pu Wang ,&nbsp;Hui Li ,&nbsp;Chu Qin ,&nbsp;Duo Miao ,&nbsp;Shaolin Xu","doi":"10.1016/j.ijmachtools.2024.104152","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2024.104152","url":null,"abstract":"<div><p>Micro-engineered glass components play a vital role in various domains, but their full potential remains untapped due to the lack of easily accessible high-precision machining methods for customizable microstructure. Our discovery of a new phenomenon, where laser-modified regions break the rule of inherently isotropic glass etching and regulate a directional anisotropic etching along modified tracks, has led to the development of a laser-guided anisotropic etching (LGAE) method. This method enables crafting precision glass microstructures with sharp features, smooth surfaces, and adjustable shapes and sizes. An ultrafast Bessel beam is utilized to create high aspect-ratio line-shaped modification within the glass. With a higher etching rate than pristine glass, the modified line guides directional anisotropic etching along the modified track, facilitating the formation of a V-shape with an angle altered by the etching ratio. These modified lines can further serve as basic building blocks to interconnect to construct a 3D internal modification region and then guide the glass's overall surface morphology etching evolution, enabling the creation of microstructures featuring designable shapes and adjustable feature sizes. To accurately predict and control the shape of the microstructures, we establish a finite difference etching model that incorporates localized etching rate regulation, validating the robustness and controllability of LGAE. This scalable method has successfully fabricated a 50 μm period micro-pyramid array with high uniformity over a centimeter-scale area, demonstrating its suitability for large-scale manufacturing. The showcased micro-engineered glass components encompass V-groove arrays for fiber alignment, blazed gratings for light modulation, and microchannels with customized trajectories for microfluidic chips. These advancements driven by LGAE can significantly contribute to the progress of glass-based research and industries.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"198 ","pages":"Article 104152"},"PeriodicalIF":14.0,"publicationDate":"2024-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140543903","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Development of a universal, machine tool independent dynamometer for accurate cutting force estimation in milling","authors":"G. Totis,&nbsp;D. Bortoluzzi,&nbsp;M. Sortino","doi":"10.1016/j.ijmachtools.2024.104151","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2024.104151","url":null,"abstract":"<div><p>When integrating a dynamometer into a machining system, it is necessary to identify the dynamic relationship between the effective input forces and the measured output signals (i.e., its transmissibility) through dedicated experimental modal analysis. Subsequently, a filter can be derived and applied to reconstruct the effective input forces from the measured signals. Unfortunately this identification phase can be complex, posing challenges to the device’s applicability in both laboratory and industrial conditions. Here this challenge is addressed by introducing a novel dynamometer concept based on both load cells and accelerometers, along with a Universal Inverse Filter. Notably, this filter is independent of the dynamic behavior of the mechanical system where the device is installed. A single calibration suffices, ideally conducted by the device manufacturer or by an expert, allowing the dynamometer’s integration by a non-expert user into any machining system without the need for repeating the identification phase and the filter generation. Furthermore, this new concept offers another significant advantage: it attenuates all inertial disturbances affecting the measured signals, including those arising from the cutting process and those originating from exogenous sources such as spindle rotation, linear axes’ movements, and other vibrations propagating through the machine tool structure. To illustrate, a simplified model is introduced initially, followed by an overview of the novel dynamometer design, innovative identification phase, and filter construction algorithm. The outstanding performance of the novel (non-parametric) Universal Inverse Filter – about 5 kHz of usable frequency bandwidth along direct directions and 4.5 kHz along cross dir. – was experimentally assessed through modal analysis and actual cutting tests, compared against state of the art filters. The efficacy of the new filter, which is even simpler than its predecessors, was successfully demonstrated for both commercial and taylor-made dynamometers, thus showing its great versatility.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"198 ","pages":"Article 104151"},"PeriodicalIF":14.0,"publicationDate":"2024-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0890695524000373/pdfft?md5=7b2a72cb9150c8966ffcfa8b9b123dc4&pid=1-s2.0-S0890695524000373-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140332811","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A chip formation mechanism taking into account microstructure evolution during the cutting process: Taking compacted graphite iron machining as an example","authors":"Jiahui Niu ,&nbsp;Chuanzhen Huang ,&nbsp;Zhenyu Shi ,&nbsp;Hanlian Liu ,&nbsp;Zhengyi Tang ,&nbsp;Rui Su ,&nbsp;Zhen Chen ,&nbsp;Binghao Li ,&nbsp;Zhen Wang ,&nbsp;Longhua Xu","doi":"10.1016/j.ijmachtools.2024.104150","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2024.104150","url":null,"abstract":"<div><p>Compacted graphite iron (CGI), a prototypical heterogeneous material, potentially demonstrates distinctive cutting deformation behaviours attributed to the random distribution of graphite and performance differences between graphite and the matrix, which have not yet received adequate attention. This study focuses on the influence of the microstructure characteristics of CGI on the formation of serrated chips. The morphology of the serrated chip segments during the orthogonal turning of CGI was observed in detail, the microstructures of the chip roots were characterised and analysed using various techniques, and a finite-element cutting simulation model considering the microstructural characteristics of CGI was developed. Results suggest that the formation of serrated chips in CGI is influenced by periodic and aperiodic brittle fractures, referred to as quasi-periodic brittle fractures, which are controlled by the distribution of graphite in CGI. This results in variations in the morphology and dimensions of the serrated chips in CGI. Plastic deformation is concentrated in a triangular deformation zone (TDZ) near the tool-chip interface, which is broader than the conventional secondary deformation zone. The experimental and simulation results revealed the reasons for the formation of the TDZ and emphasized the critical role of graphite in the formation of serrated chips in CGI. The graphite particles near the tool-chip interface promoted plastic deformation along the interface owing to the principle of minimum energy and restricted deformation perpendicular to the interface due to its structure, leading to the formation of the TDZ. The influence of graphite on material flow and the formation of the TDZ during the formation of serrated chips in CGI is a novel discovery. The microstructure evolution of the pearlite matrix in CGI caused by cutting deformation was analysed. The results demonstrate that the distinctive deformation behaviour of CGI contributes to the fragmentation of the pearlite structure, grain refinement, and increased dislocation density in the TDZ. Finally, the influence of the serrated chip formation mechanism on chip morphology and cutting force in CGI was discussed. These findings offer significant scientific insights and contribute to the fundamental understanding of the chip formation process in CGI.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"198 ","pages":"Article 104150"},"PeriodicalIF":14.0,"publicationDate":"2024-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140345161","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation on low hydrostatic stress extrusion technology for forming of large thin-walled components with high ribs","authors":"Zhimin Zhang ,&nbsp;Zhe Chen ,&nbsp;Yong Xue ,&nbsp;Xing Zhang ,&nbsp;Qiang Wang","doi":"10.1016/j.ijmachtools.2024.104149","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2024.104149","url":null,"abstract":"<div><p>An increase in hydrostatic stress improves the plasticity of metallic materials. However, for some special components, such as large thin-walled components with high ribs, excessive hydrostatic stress can cause several problems that make it impossible to prepare such components using plastic forming methods. In this study, the effect of hydrostatic stress on the deformation behavior of large thin-walled components with high ribs was investigated using a combination of numerical simulations and theoretical derivations. The results indicated that excessive hydrostatic stress leads to die failure, causing metal flow difficulties, uneven deformation, inconsistent mechanical properties, and reduced forming accuracy. Therefore, a low-hydrostatic-stress extrusion method was proposed by adjusting the contact friction, metal flow direction and displacement, and force boundary conditions to reduce the hydrostatic compressive stress. These principles are mainly reflected in the following three aspects: First, the size of the difficult deformation zone was reduced by changing the friction conditions from dry friction to fluid friction or boundary friction to reduce the frictional resistance. Second, the high-stress zone was eliminated by changing the metal flow direction, adjusting the strain state from unidirectional to multi-directional flow, shortening the metal flow path, and reducing the metal flow resistance. Third, the strong compressive stress state in the three directions was weakened by regulating the force boundary conditions and changing the loading method from one-way extrusion to multi-directional loading. Based on these principles, a series of new forming technologies have been developed, such as actively counteracting frictional resistance, slotting, and ditching on dies for long-lasting lubrication, multi-directional short-range metal flow, drawing-assisted extrusion, and multi-directional active loading. The adoption of these technologies realizes the labor-efficient formation of large thin-walled components with high ribs and provides the formed members with high precision and uniform mechanical properties.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"198 ","pages":"Article 104149"},"PeriodicalIF":14.0,"publicationDate":"2024-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140309696","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"On wear of TiAlN coated tools with and without NbN overlayer in machining titanium alloys","authors":"Rebecka Lindvall ,&nbsp;Filip Lenrick ,&nbsp;Jon M. Andersson ,&nbsp;Rachid M'Saoubi ,&nbsp;Volodymyr Bushlya","doi":"10.1016/j.ijmachtools.2024.104148","DOIUrl":"10.1016/j.ijmachtools.2024.104148","url":null,"abstract":"<div><p>Finding a wear resistant coating for cemented carbide cutting tools in the machining of difficult to cut Ti alloys is a challenge due to their high strength and chemical reactivity. Tool manufacturers recommend physical vapor deposited (PVD) Ti_xAl_1-xN (x = 0.4–0.7), and an extra NbN overlayer has shown promising potential. This study explores wear mechanisms of PVD Ti_0.45Al_0.55N with and without NbN overlayer and its WC-Co substrate in machining Ti alloys. To achieve an accurate understanding of tool-chip-workpiece interaction and related wear mechanisms, several approaches were employed. Tests with controlled variation of cutting speeds were complemented by process freezing experiments using the quick stop method and imitational experiments of diffusion couples. Advanced microscopy techniques were employed for accurate detection of wear products and phenomena across length scale. Findings reveal that any new design of coatings for Ti machining must combine both high mechanical integrity and resistance to diffusional dissolution and oxidation. Observed diffusional loss of Al and N from the coating results in a TiN layer which is mechanically weaker than the original coating, while the NbN overlayer reduces the Al diffusion rate, but NbN is subjected to diffusional dissolution itself. On dissolution, Nb stabilizes β-Ti and thus facilitating loss of Al, but the observed formation of intermetallic Nb₃Al at the NbN–Ti interface works as a diffusion barrier. However, brittle Nb₃Al can be more easily removed during machining. It was found that the coating retains longest on the edge line and protects the tool edge from failure because substrate cemented carbide wears at a faster rate than the coating with outward diffusion of C from WC grains and Co binder.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"198 ","pages":"Article 104148"},"PeriodicalIF":14.0,"publicationDate":"2024-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0890695524000348/pdfft?md5=43536bfd8266568bb821eb7e0bc9526b&pid=1-s2.0-S0890695524000348-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140277613","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Low-frequency vibration assisted self-pierce riveting (LV-SPR) of carbon fiber reinforced composite and aluminum alloy","authors":"Cong Shao,&nbsp;Jun Lin,&nbsp;Yanjin Guan,&nbsp;Dong Quan,&nbsp;Liang Chen,&nbsp;Cunsheng Zhang,&nbsp;Guoqun Zhao","doi":"10.1016/j.ijmachtools.2024.104147","DOIUrl":"https://doi.org/10.1016/j.ijmachtools.2024.104147","url":null,"abstract":"<div><p>Self-pierce riveting (SPR) has been widely applied to join carbon fiber-reinforced polymer (CFRP) composites and high-strength metallic plates in the automotive and aerospace fields. However, the CFRP is often damaged by rivet piercing owing to its brittleness as well as the relatively small interlocking that forms between the rivet leg and high-strength plate owing to the hard deformation characteristics. Therefore, in this study, a novel low-frequency vibration-assisted self-pierce riveting (LV-SPR) technology is proposed, which utilizes the vibration effect in softening the metal and reducing interfacial friction at room temperature. In riveting experiments involving CFRP and 5052 aluminum alloy utilizing 37Cr4 semi-hollow rivets, LV-SPR exhibited a significant reduction of 68.2% in the riveting force compared to the traditional SPR process. The decreased riveting pressure in LV-SPR effectively mitigated the CFRP damage by 36.2%, which was caused by a reduction in the interfacial friction force between the rivet and CFRP laminate. Moreover, owing to the improved deformation capacity of the rivet and alloy plate by the vibration softening effect, the lateral expansion of the rivet leg in the aluminum alloy was enlarged by 36.4% compared to that using the traditional self-piercing riveting (T-SPR) process. Microscopic characterization revealed that vibrations notably promoted grain refinement and enlarged the subgrain structures of the rivets and alloy plates. Finally, by superposing oscillations, the shear strength of the connection joint increased by 13.5% compared to the T-SPR joint. The proposed LV-SPR was validated as an effective technique to increase the connection strength of high-performance plates, which can efficiently improve the structural safety and promote the widespread application of CFRP/alloys in automobiles and aircrafts.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"197 ","pages":"Article 104147"},"PeriodicalIF":14.0,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140187355","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Development of a novel bulk metallic glass bonded single-layer diamond wheel","authors":"Dandan Wu ,&nbsp;Zijun Liu ,&nbsp;Yufu Yan ,&nbsp;Qiaosen Liang ,&nbsp;Liyan Luo ,&nbsp;Chengyong Wang","doi":"10.1016/j.ijmachtools.2024.104146","DOIUrl":"10.1016/j.ijmachtools.2024.104146","url":null,"abstract":"<div><p>A novel manufacturing process was employed to develop a single-layer diamond wheel using bulk metallic glass (BMG) as the matrix and diamond particles as abrasives. BMG effectively prevented graphitisation and damage to the diamond abrasives because of its lower manufacturing temperature and avoidance of brazing flux. The Titanium (Ti) coating on the surface of diamond abrasives facilitated the formation of an interleaved dissolution-diffusion interface between the two constituents, creating mechanical occlusion at the BMG-diamond interface. The strong and tight bonding interface afforded a diamond abrasive joint strength of up to 112.59 N, with the main shear failure mode being transgranular fracture instead of pull-off failure. Furthermore, the manufactured BMG-bonded single-layer diamond wheel predominantly exhibited attritious wear instead of the exfoliation of abrasives when grinding Al₂O₃ ceramics. Compared with contemporary electroplated grinding wheels, the developed diamond wheel demonstrated a reduction in the normal and tangential grinding forces of 32.64% and 35.86%, respectively, and a 28.22% increase in the grinding ratio, making it an excellent candidate for grinding hard and brittle materials.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"197 ","pages":"Article 104146"},"PeriodicalIF":14.0,"publicationDate":"2024-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140069809","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Topography prediction of high-aspect ratio features milled with overlapping abrasive slurry jet footprints considering fluid confinement effects","authors":"Majid Moghaddam,&nbsp;Marcello Papini","doi":"10.1016/j.ijmachtools.2024.104145","DOIUrl":"10.1016/j.ijmachtools.2024.104145","url":null,"abstract":"<div><p>Overlapping adjacent passes of abrasive slurry jets can be used to fabricate micro-pockets or blind micro-slots. This study investigates the propagation of surfaces milled using overlapping passes of a high-pressure abrasive slurry jet on a ductile 6061-T6 target over a wide range of aspect ratios. Features such as shallow pockets with low aspect ratios to deep slots with aspect ratios ∼1.5 were fabricated to investigate the correlations between the aspect ratio, degree of pass overlap, and number of repeating passes with the machined surface evolution characteristics. A comprehensive model was presented that combined computational fluid dynamics (CFD) with surface evolution to predict the evolving machined feature topography after each of the overlapping and repeating passes, and to provide insights into experimental observations. The model explicitly considered the CFD-predicted local particle impact angles and velocities as well as effects due to secondary impacts, high sidewall slopes, and stagnation effects. For larger degrees of overlap, measurements revealed a more than linear rate of increase in depth after each repeat of two adjacent overlapped passes, as opposed to a linear depth increase for smaller overlaps and blind pockets. Large overlaps were found to result in asymmetric features. Up to a critical aspect ratio of ∼0.65, the model predicted the surface evolution of the features to within &lt;8.6% of those measured. Beyond that, randomness in the machined feature shape and size made the process challenging to control and the surface evolution difficult to predict. Nevertheless, the model was able to elucidate the reasons for the randomness and other observed phenomena such as the more than linear growth in etch rate, and the occurrence of feature asymmetry. The findings emphasize that flow confinement, increases in the jet's turbulent kinetic energy, and the formation of vortices at the bottom of the machined features are critical factors influencing the machining process, and that in these cases explicit modeling approaches like the one presented in this study must be used.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"197 ","pages":"Article 104145"},"PeriodicalIF":14.0,"publicationDate":"2024-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0890695524000312/pdfft?md5=60044025e91af0a76dd076b53baa1eac&pid=1-s2.0-S0890695524000312-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140069800","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Concurrent process and feedrate scheduling with convoluted basis functions and its application to fluid jet polishing","authors":"Shuntaro Yamato ,&nbsp;Burak Sencer ,&nbsp;Anthony Beaucamp","doi":"10.1016/j.ijmachtools.2024.104135","DOIUrl":"10.1016/j.ijmachtools.2024.104135","url":null,"abstract":"<div><p>Non-traditional laser and fluid jet processes exhibit time-dependent material removal characteristics. The feedrate profile must be planned carefully along the toolpath for accurate surface profile generation while ensuring that the kinematic limits of machine tools are not violated. Conventional methods iteratively solve a deconvolution/convolution problem on the dwell-time density (reciprocal of the feedrate profile) that is computationally heavy, may leave significant residual processing errors, and even generate infeasible feed profiles with the manufacturing equipment. This paper proposes a novel approach that fully addresses the shortcomings above. Dwell-time density is first expressed as a continuous B-spline profile. The associated dwell basis functions (DBF) are convolved with the process influence function (PIF) to generate new process basis functions (PBF). This approach conveniently allows the posing of the problem as a concurrent linear least-squares problem on the control points shared by the DBFs and PBFs while ensuring the numerical stability of the solution and smoothness of the feed profile. To mitigate excessive acceleration peaks and any ringing effect around the edges of the toolpath, this paper also presents methodologies for stabilizing the scheduled feedrate profile by introducing knot vector adjustments (adaptive knot dropping) and linear edge constraints. The effectiveness of the proposed method is demonstrated and validated through simulation case studies and experimentally in fluid jet processing of precision optics. Results indicate that the proposed technique overcomes the limitations of conventional strategies and allows high-frequency surface components beyond the first zero-power frequency of the process footprint to be tracked while still generating a smooth feed profile within the acceleration limits of a machine tool. This ability stems from the localization characteristics associated with the basis functions. By improving the accuracy of high-frequency components, the proposed method exhibits the potential to fabricate topographies with sharper edges, which has been a challenge for conventional techniques.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"197 ","pages":"Article 104135"},"PeriodicalIF":14.0,"publicationDate":"2024-02-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140020221","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhanced steel machining performance using texture-controlled CVD alpha-alumina coatings: Fundamental degradation mechanisms","authors":"S. Shoja ,&nbsp;O. Bäcke ,&nbsp;A. Fazi ,&nbsp;S. Norgren ,&nbsp;H.-O. Andrén ,&nbsp;M. Halvarsson","doi":"10.1016/j.ijmachtools.2024.104137","DOIUrl":"10.1016/j.ijmachtools.2024.104137","url":null,"abstract":"<div><p>Cemented carbide inserts coated with CVD α-alumina, particularly those exhibiting a (0001) texture, have proven highly effective in steel turning. Despite the established superior performance of (0001) textured alumina coatings, the underlying reasons remain unclear. This study explores the influence of the crystallographic texture of alumina on wear mechanisms in various chip-tool contact zones on the insert rake face. The objective is to establish a fundamental understanding of the active degradation mechanisms and machining performance by relating coating texture to the orientation and deformation of individual Al₂O₃ grains. Two multilayered coatings, Al₂O₃ on Ti(C,N), featuring (0001)- and <span><math><mrow><mo>(</mo><mrow><mn>11</mn><mover><mn>2</mn><mo>‾</mo></mover><mn>0</mn></mrow><mo>)</mo></mrow></math></span>-textured CVD α-alumina, were assessed in dry turning of a bearing steel. The wear rate of the <span><math><mrow><mo>(</mo><mrow><mn>11</mn><mover><mn>2</mn><mo>‾</mo></mover><mn>0</mn></mrow><mo>)</mo></mrow></math></span> coating was double that of the (0001) coating. Worn coatings exhibit nano-terrace formation at the insert edge, likely due to chemical etching. In the sticking zone, plastic deformation leads to larger facets for grains oriented with the chip flow direction, while rounded surfaces result if this condition is not met. In the transition zone, both (0001) and <span><math><mrow><mo>(</mo><mrow><mn>11</mn><mover><mn>2</mn><mo>‾</mo></mover><mn>0</mn></mrow><mo>)</mo></mrow></math></span> textured coatings undergo increased plastic deformation accompanied by sub-surface dislocations. (0001) texture deforms more by basal slip creating a wavy coating pattern with steps present at larger misalignments of the lattice planes in neighboring grains while <span><math><mrow><mo>(</mo><mrow><mn>11</mn><mover><mn>2</mn><mo>‾</mo></mover><mn>0</mn></mrow><mo>)</mo></mrow></math></span> texture deforms by several slip systems creating elongated ridges and ruptured-like areas resulting in rougher surface. This difference in surface morphology is then inherited by the abrasion of submicron coating fragments embedded in the chip (more in <span><math><mrow><mo>(</mo><mrow><mn>11</mn><mover><mn>2</mn><mo>‾</mo></mover><mn>0</mn></mrow><mo>)</mo></mrow></math></span> texture) in the sliding zone resulting in an even rougher surface. Chemical reaction with the hot chip may also contribute to wear acting as an additional mechanism. This fundamental understanding contributes to the potential enhancement of steel machining using texture-controlled CVD alumina coatings, ultimately improving coated cutting tool performance.</p></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"197 ","pages":"Article 104137"},"PeriodicalIF":14.0,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140020252","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}