Advertisement

Tribology of Composite Materials and Coatings in Manufacturing

  • M. H. SulaimanEmail author
  • N. A. Raof
  • A. N. Dahnel
Chapter
First Online:
  • 22 Downloads
Part of the Composites Science and Technology book series (CST)

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.

Keywords

Manufacturing Lubricant-free forming Cryogenic machining Composite coating Ultrasonic assisted drilling (UAD) Carbon fibre composite (CFC) Titanium alloy composite 
This is a preview of subscription content, log in to check access.

Notes

Acknowledgements

The authors are grateful for the support from Tribology Innovations for Manufacturing (TriboMAN) IIUM research group. M.H. Sulaiman would like to thank Taiho Kogyo Tribology Research Foundation (TTRF) for the financial support, and CemeCon Scandinavia A/S for the coatings.

References

  1. 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.2017.03.197CrossRefGoogle Scholar
  2. Azarhoushang B, Akbari J (2007) Ultrasonic-assisted drilling of Inconel 738-LC. Int J Mach Tools Manuf 47:1027–1033CrossRefGoogle Scholar
  3. Babitsky V, Astashev V, Meadows A (2007) Vibration excitation and energy transfer during ultrasonically assisted drilling. J Sound Vib 308:805–814CrossRefGoogle Scholar
  4. 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 1–10Google Scholar
  5. 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 1–8Google Scholar
  6. 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 7–04Google Scholar
  7. 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.2011.02.009CrossRefGoogle Scholar
  8. 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.2010.02.008CrossRefGoogle Scholar
  9. 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.2013.03.062CrossRefGoogle Scholar
  10. 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.966-967.219CrossRefGoogle Scholar
  11. Chang S, Bone G (2005) Burr size reduction in drilling by ultrasonic assistance. Robot Comput Integr Manuf 21:442–450CrossRefGoogle Scholar
  12. Chuan P, Ghani JA, Jameelah M, Ria T (2013) Characterization of TiCN and TiCN/ZrN coatings for cutting tool application. Ceram Int 39:1293–1298CrossRefGoogle Scholar
  13. 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.2013.04.010CrossRefGoogle Scholar
  14. Dahnel AN (2017) Conventional and ultrasonic assisted drilling of carbon fibre reinforced polymer/titanium alloy stacks (Doctoral dissertation, University of Warwick)Google Scholar
  15. 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 1–10Google Scholar
  16. 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.2016.04.044CrossRefGoogle Scholar
  17. de Neergaard A (2017) Personal communication with M.H. SulaimanGoogle Scholar
  18. 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)00825-0CrossRefGoogle Scholar
  19. 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 398–399:90–98CrossRefGoogle Scholar
  20. 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.2013.12.001CrossRefGoogle Scholar
  21. 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)00029-3CrossRefGoogle Scholar
  22. 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)00041-4CrossRefGoogle Scholar
  23. Hosseini A, Kishawy H (2014) Cutting tool materials and tool wear. In: Davim J (ed) Machining of titanium alloys. Springer, BerlinGoogle Scholar
  24. 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.2016.06.007CrossRefGoogle Scholar
  25. 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/s00170-014-5683-0CrossRefGoogle Scholar
  26. 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 123–128Google Scholar
  27. 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.2013.06.140CrossRefGoogle Scholar
  28. 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.2013.05.011CrossRefGoogle Scholar
  29. 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.2007.05.070CrossRefGoogle Scholar
  30. 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
  31. Li R, Shih A (2007) Tool temperature in titanium drilling. J Manuf Sci Eng 129:740–749CrossRefGoogle Scholar
  32. Liu D, Tang Y, Cong W (2012) A review of mechanical drilling for composite laminates. Compos Struct 94:1265–1279CrossRefGoogle Scholar
  33. 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
  34. Makhdum F, Phadnis VA, Roy A, Silberschmidt VV (2014) Effect of ultrasonically assisted drilling on carbon fibre reinforced plastics. J Sound Vib 333:5939–5952CrossRefGoogle Scholar
  35. 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 1:121–133Google Scholar
  36. 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.2006.06.013CrossRefGoogle Scholar
  37. 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-DCrossRefGoogle Scholar
  38. Pecat O, Brinksmeier E (2014) Tool wear analyses in low frequency vibration assisted drilling of CFC/Ti6Al4V stack material. Procedia CIRP 14:142–147CrossRefGoogle Scholar
  39. Pu Z (2012) Cryogenic machining and burnishing of AZ31B magnesium alloy for enhanced surface integrity and functional performanceGoogle Scholar
  40. 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.2011.03.096CrossRefGoogle Scholar
  41. 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 8:4347–4353CrossRefGoogle Scholar
  42. Rotella G, Umbrello D, Dillon OW, Jawahir IS (2012) Evaluation of process performance for sustainable hard machining. J Adv Mech Des Syst Manuf 6:989–998CrossRefGoogle Scholar
  43. 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.2012.02.002CrossRefGoogle Scholar
  44. 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.2012.749531CrossRefGoogle Scholar
  45. 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 51:569–578CrossRefGoogle Scholar
  46. 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/10.1177/0954405413486635CrossRefGoogle Scholar
  47. Sulaiman MH (2017) Development and testing of tailored tool surfaces for sheet metal formingGoogle Scholar
  48. 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 1–6Google Scholar
  49. Sulaiman MH, Christiansen P, Bay N (2017b) A study of anti-seizure tool coatings for ironing of stainless steel. J Tribol Spec Issue WTC2017 17:1–11Google Scholar
  50. 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 670:012052CrossRefGoogle Scholar
  51. 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 438–439:203040CrossRefGoogle Scholar
  52. 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.2011.05.002CrossRefGoogle Scholar
  53. Tool-life testing with single-point turning tools. STN ISO 3685 (1993)Google Scholar
  54. 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
  55. 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/s00170-014-5673-2CrossRefGoogle Scholar
  56. Wang Z, Rajurkar K (1997) Wear of CBN tool in turning of silicon nitride with cryogenic cooling. Int J Mach Tools Manuf 37:319–326CrossRefGoogle Scholar
  57. Wang ZY, Rajurkar KP (2000) Cryogenic machining of hard-to-cut materials. Wear 239:168–175.  https://doi.org/10.1016/S0043-1648(99)00361-0CrossRefGoogle Scholar
  58. 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.2006.07.015CrossRefGoogle Scholar
  59. 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 317:265–276CrossRefGoogle Scholar
  60. Yasa E, Pilatin S, Çolak O (2012) Overview of cryogenic cooling in machining of Ti alloys and a case study. J Prod Eng 2:1–9Google Scholar
  61. 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 186:108207CrossRefGoogle Scholar
  62. 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.2018.09.013CrossRefGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2021

Authors and Affiliations

  1. 1.Department of Manufacturing and Materials Engineering, Kulliyyah of EngineeringInternational Islamic University MalaysiaKuala LumpurMalaysia

Personalised recommendations

Cite chapter

Buy options