Title:
Shot-peening-based mechano-chemical surface modification for friction and wear reduction in cutting tools
Shot-peening-based mechano-chemical surface modification for friction and wear reduction in cutting tools
Author(s)
Qi, Ye
Advisor(s)
Varenberg, Michael
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Abstract
In machining processes, higher friction and wear can result in more frequent tool replacement, higher energy consumption, lower dimensional accuracy, and inferior surface quality. Therefore, methods to modify cutting tool surfaces to improve their tribological performance, thus leading to more sustainable and efficient machining, are of great importance to the manufacturing industry and to the research community. Here, a mechano-chemical surface modification is proposed to improve cutting tools’ performance. The approach consists of modifying the rake faces of cutting tools through localized plastic deformation of the near-surface region accompanied by a simultaneous exposure to a proper chemical precursor. Shot peening with a mixture of Al2O3 and Cu2S particles, with the former serving as the mechanical agent that enhances the chemical reactivity of the surface through plastic deformation and the latter serving as a chemical precursor, will be utilized to form a lubricious layer on the cutting tool surfaces.
The potential and capability of the shot-peening-based mechano-chemical surface modification of cutting tools were explored both theoretically and experimentally in the following way. 1) A deterministic model coupled with finite element, transient thermal, and reaction rate simulation was developed to estimate the reaction kinetics of mechano-chemical reaction between Cu2S and Fe thus provide theoretical support of the proposed modification technique. 2) The effect of mechano-chemical surface modification of high-speed steel (HSS) cutting tools on the reduction of cutting forces was investigated and supplemented with the analysis of surface chemistry and topography. 3) The effects of critical surface modification parameters on the surface chemistry, topography, and hardness were studied and correlated to the machining performance of HSS cutting tools. 4) The wear resistance of mechano-chemically modified HSS tools was examined along with the corresponding changes in the surface properties. 5) WC inserts were mechano-chemically modified to examine cutting forces and tool wear with respect to the chemical composition, roughness and residual stresses of the tested tool surfaces.
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Date Issued
2021-08-02
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Text
Resource Subtype
Dissertation