Adaptive Surface Engineering of High Performance Manufacturing Tooling

高性能制造工具的自适应表面工程

• 批准号: RGPIN-2014-04380
• 负责人: Veldhuis, Stephen
• 金额: $ 2.4万
• 依托单位: McMaster University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2018
• 资助国家: 加拿大
• 起止时间: 2018-01-01 至 2019-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=667695
• 关键词: Adaptive; Surface; Engineering; Performance; Manufacturing

Manufacturing is an important part of the Canadian economy and continues to hold considerable promise as global economic growth drives the demand for manufactured goods. Being in a high labour cost region Canadian industry has had to make significant investments in advanced manufacturing equipment in order to be competitive. Tooling plays an important role in how effective this large capital base of equipment is as it often sets the productivity level, impacts cost and quality and in many cases limits the types of materials that can be processed. Coatings have been shown to greatly enhance the performance of tooling by providing added wear protection and lubricity.**As part of my previous Discovery Grant, a novel nano-multilayered TiAlCrSiYN/TiAlCrN PVD coating was developed for machining hard to cut materials. This development was based on enhancing the ability of the coating to adapt to its conditions by forming lubricious and protective tribofilms. The main purpose of this proposed research program is to better understand the tribofilm formation mechanisms which underlie this improvement and use this knowledge to develop a new generation of adaptive surface engineered solutions which form protective and lubricious tribofilms tailored to the specific requirements of the application. **The major impact of this research will be to develop a deeper understanding of how protective and lubricious tribofilms are generated and sustained over the life of a tool and the role they play in reducing friction and wear. These aspects will be explored by altering coating composition and microstructure and by using ion implantation and fine particle bombardment techniques as well as selective workpiece alloying, for example. These techniques will be applied with the aim of generating the initial surface conditions needed to favourably adapt the tool and activate the tribo-chemical reactions during the initial running-in stage of wear. This is important as the running-in stage has a big impact on overall wear behaviour.**Given that tribofilms are very delicate in nature, innovative sample preparation techniques will be developed to better preserve the tribofilms on the extremely hard tool materials. These will be applied to establish the chemical composition and structure of the tribofilms, including the nature of its bond with the tool substrate and its evolution over time. This information will then be correlated to friction properties, as well as wear rates and wear mechanisms for specific tool, workpiece and environment combinations.**Once beneficial surface treatments are developed detailed optimization studies will be performed to establish the machine operating conditions which fully exploit the beneficial properties of the tribofilms. Following detailed laboratory testing the surface treatments will be tested in production at our industrial partners' sites. This collaboration provides a direct link of our academic research to the Canadian manufacturing industry and will lead to quick adoption of the novel solutions. **The knowledge gained from this research will enhance the productivity of machining operations by developing solutions able to withstand the extreme operating conditions associated with high performance machining and new difficult to cut alloys. The improved lubricity of at the tool interface will enhance quality by reducing the surface and subsurface damage generated by poor chip formation and flow. The longer tool life expected will reduce tooling cost per part as well as the amount of low value added manual labour associated with setting up and changing tools and tracking offsets. Collectively these improvements represent a significant competitive edge that will drive growth in Canadian manufacturing.

制造业是加拿大经济的重要组成部分，并且随着全球经济增长推动对制成品的需求而继续保持巨大的希望。加拿大行业的劳动力成本高，必须在高级制造设备上进行大量投资才能具有竞争力。工具在设备的庞大资本基础方面发挥了重要作用，因为它通常设定生产率水平，影响成本和质量，并且在许多情况下限制了可以处理的材料的类型。涂料已被证明可以通过提供添加的磨损保护和润滑性来大大提高工具的性能。这一发展是基于增强涂层通过形成润滑性和保护性摩擦膜来适应其条件的能力。该提出的研究计划的主要目的是更好地了解这种改进并利用这些知识来开发新一代自适应地面工程解决方案的摩擦膜形成机制，这些解决方案构成了针对应用程序特定要求量身定制的保护性和润滑性的互感。 **这项研究的主要影响将是对在工具的生命中产生和维持的保护性和润滑性摩擦膜在减少摩擦和磨损中的作用。 例如，将通过改变涂料组成和微观结构，使用离子植入和细颗粒轰击技术以及选择性工件合金来探索这些方面。 这些技术将应用于生成有利的适应该工具并在磨损初始跑步阶段激活的初始表面条件的目的。这很重要，因为跑步阶段对整体磨损行为具有很大的影响。这些将应用于建立互感的化学组成和结构，包括其与刀具底物的结合性质及其随着时间的推移的进化。然后，该信息将与摩擦特性以及针对特定工具，工件和环境组合的磨损率和磨损机制相关。经过详细的实验室测试，将在我们的工业合作伙伴站点的生产中测试表面处理。这项合作提供了我们的学术研究与加拿大制造业的直接联系，并将迅速采用新颖的解决方案。 **这项研究所获得的知识将通过开发能够承受与高性能加工相关的极端操作条件和新的难以削减合金的极端操作条件来提高加工操作的生产率。在工具界面上的润滑性提高将通过减少芯片形成和流动不良产生的表面和地下损害来提高质量。预期的工具寿命较长将降低每个零件的工具成本，以及与设置和更改工具以及跟踪偏移相关的低值手动劳动力的数量。这些改进共同代表了一个重要的竞争优势，该优势将推动加拿大制造业的增长。