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Materials Forming, Machining and Tribology For furthervolumes: http://www.springer.com/series/11181 J. Paulo Davim Editor Tribology in Manufacturing Technology 123 Editor J.Paulo Davim Department of Mechanical Engineering Campus Santiago Universityof Aveiro Aveiro Portugal ISSN 2195-0911 ISSN 2195-092X (electronic) ISBN 978-3-642-31682-1 ISBN 978-3-642-31683-8 (eBook) DOI 10.1007/978-3-642-31683-8 SpringerHeidelbergNewYorkDordrechtLondon LibraryofCongressControlNumber:2012943973 (cid:2)Springer-VerlagBerlinHeidelberg2012 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartof the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionor informationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodology now known or hereafter developed. Exempted from this legal reservation are brief excerpts in connection with reviews or scholarly analysis or material supplied specifically for the purposeofbeingenteredandexecutedonacomputersystem,forexclusiveusebythepurchaserofthe work. Duplication of this publication or parts thereof is permitted only under the provisions of theCopyrightLawofthePublisher’slocation,initscurrentversion,andpermissionforusemustalways beobtainedfromSpringer.PermissionsforusemaybeobtainedthroughRightsLinkattheCopyright ClearanceCenter.ViolationsareliabletoprosecutionundertherespectiveCopyrightLaw. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexempt fromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. While the advice and information in this book are believed to be true and accurate at the date of publication,neithertheauthorsnortheeditorsnorthepublishercanacceptanylegalresponsibilityfor anyerrorsoromissionsthatmaybemade.Thepublishermakesnowarranty,expressorimplied,with respecttothematerialcontainedherein. Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) Preface Tribologyisthescienceandengineeringofinteractingsurfacesinrelativemotion and associated issues, such as friction, lubrication, and wear. It incorporates various disciplines such as surface physics and chemistry, fluid mechanics, materials, contact mechanics, and lubrication systems. Tribology has an important role in manufacturing technology because all processes involve surface contact mechanics. Manufacturing processes of many kinds involve tribological considerations. Several examples have been chosen to illustrate how the tribological concepts have been applied to improve the manufacturing technology. The Chap. 1 of the book provides tribology of cutting tools. Chapter 2 is dedicated to the tribology of machining. Chapter 3 described tribology in metal forming processes. Chapter 4 contains information on tribology in hot rolling of steelstripandChap.5isdedicatedofmicrocontactatinterfacebetween tooland andworkpieceinmetalforming.Finally,Chap.6containsinformationoncoatings and applications. The present book can be used as a research book for final undergraduate engineeringcourseorasatopiconmanufacturingatthepostgraduatelevel.Also, this book can serve as a useful reference for academics, tribology, and manufacturing researchers, manufacturing, materials, and mechanical engineers, profes- sional in manufacturing, and related industries. The interest of scientific in this book is evident for many important centers of the research, laboratories, and universities as well as industry. Therefore, it is hoped this book will inspire and enthuse others to undertake research in this field of tribology in manufacturing technology. TheEditoracknowledgesSpringerforthisopportunityandfortheirenthusiastic andprofessional support.Finally,Iwouldlike tothank allthe chapter authorsfor their availability for this work. Aveiro, Portugal, August 2012 J. Paulo Davim v Contents 1 Tribology of Cutting Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Viktor P. Astakhov 2 Tribology of Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 M. J. Jackson, M. Whitfield, G. M. Robinson, J. Morrell and J. P. Davim 3 Tribology in Metal Forming Processes . . . . . . . . . . . . . . . . . . . . . 103 Sergio Tonini Button 4 Tribology in Hot Rolling of Steel Strip. . . . . . . . . . . . . . . . . . . . . 121 D. B. Wei and Z. Y. Jiang 5 Micro-Contact at Interface Between Tool and Workpiece in Metalforming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Akira Azushima 6 Coating and Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Cássio A. Suski and C. A. S. de Oliveira Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 vii Contributors Viktor P. Astakhov 1792 ElkLn, Okemos, MI 48864, USA, e-mail: astakhov@ scientist.com Akira Azushima Department of Mechanical Enginering, Yokohama National University, 79-5 Tokiwadai Hodogaya-ku, Yokohama 204-8501, Japan, e-mail: [email protected] Sérgio Tonini Button Department of Materials Engineering, School of Mechanical Engineering, University of Campinas, Campinas, Brazil, e-mail: [email protected] J. P. Davim Department of Mechanical Engineering, University of Aveiro, Campus Santiago, Aveiro 3810-193, Portugal, e-mail: [email protected] Z. Y. Jiang School of Mechanical, Materials and Mechatronic Engineering, University of Wollongong, Wollongong, NSW 2522, Australia, e-mail: jiang@ uow.edu.au M. J. Jackson Center for Advanced Manufacturing, Purdue University, West Lafayette, IN, USA, e-mail: [email protected] J. Morrel Y-12 National Security Complex, Oak Ridge, TN, USA, e-mail: [email protected] C. A. S. de Oliveira Mechanical Engineering Department, Universidade Federal de Santa Catarina, Florianópolis, SC, Brazil, e-mail: [email protected] G. M. Robinson Center for Advanced Manufacturing, Purdue University, West Lafayette, IN, USA ix x Contributors Cássio A. Suski Instituto Federal Catarinense, 3122 St, n. 340, apt. 901, Balneário Camboriú, SC 88330-290, Brazil, e-mail: [email protected] M. Whitfield Center for Advanced Manufacturing, Purdue University, West Lafayette, IN, USA D. B. Wei School of Mechanical, Materials and Mechatronic Engineering, University of Wollongong, Wollongong, NSW 2522, Australia, e-mail: dwei@ uow.edu.au Chapter 1 Tribology of Cutting Tools Viktor P. Astakhov Abstract This chapter introduces the concept of the cutting tool tribology of a part of the metal cutting tribology. It argues that the importance of the subject became actual only recently because the modern level of the components of the machining system can fully support improvements in the cutting tool tribology. The underlying principle for tribological consideration is pointed out. The major parametersofthetribologicalinterfaces,namelythetool-chipandtool-workpiece interfaces are considered. The chapter also describes an emerging mechanism of tool wear known as cobalt leaching. The rest of the chapter presents some improvements of tribological conditions of cutting tools as the use of application specific grades of tool materials, advanced coating and high-pressure metal working fluid (MWF) supply. 1.1 What is Tribology of Cutting Tools? 1.1.1 Tribology of Metal Cutting ThetermtribologycomesfromtheGreekwordtribos,meaningfriction,andlogos, meaning law. Tribology is therefore defined as ‘‘the science and technology of interactive surfaces moving in relation to each other.’’ The science of Tribology concentrates oncontact physics andthe mechanicsof movinginterfaces thatgen- erallyinvolveenergydissipation.Itsfindingsareprimarilyapplicableinmechanical engineeringanddesignwheretribologicalinterfacesareusedtotransmit,distribute V.P.Astakhov(&) GeneralMotorsBusinessUnitofPSMi,1792ElkLn,Okemos,MI48864,USA e-mail:[email protected] J.P.Davim(ed.),TribologyinManufacturingTechnology,MaterialsForming, 1 MachiningandTribology,DOI:10.1007/978-3-642-31683-8_1, (cid:2)Springer-VerlagBerlinHeidelberg2012 2 V.P.Astakhov and/orconvertenergy.Thecontactbetweentwomaterials,andthefrictionthatone exercises on the other, causes an inevitable process of wear. What those contact conditionsare,howtostrengthentheresistanceofcontactsurfacestotheresulting wear, as well as optimizing the power transmitted by mechanical systems and complex lubrication they require, have become a specialized applied science and technical discipline which has seen major growth in recent decades. Bearing the rather colorful name ‘‘Applied tribology,’’ this field of research and application encompassesthescientificfieldsofcontactmechanics,kinematics,appliedphysics, surface topology, hydro- and thermodynamics, and many other engineering fields under a common umbrella, related to a great variety of physical and chemical processesandreactionsthatoccurattribologicalinterfaces. Whenitcomestometalcutting,tribologyisthoughtofassomethingthathasto be studied in order to reduce the tool wear (and thus increase tool life). Although thisistrueingeneral,itdoesnotexhausttheapplicationoftribologicalknowledge inmetalcutting.Unfortunately,thepublishedbooksandarticlesonthesubjectdo not treat the subject in a systematic way. Rather, the collection of non-correlated factsontoolmaterials,cuttingregimes,toollifeanditsassessment,cuttingfluids, toolcoatings,etc.,isconsideredasthetribologyofmetalcutting.Havingreadthe known works and related materials, one does not feel thoroughly equipped to analyze and improve the tribological conditions in various metal cutting opera- tions. This is because of the commonly understood meaning of ‘‘metal cutting tribology,’’ which is something related to reduction of tool wear, its assessment and reduction. Althoughit is truethat cutting tool wear andits proper assessment is a part of metal cutting tribology, the assessment and reduction of tool wear are only ‘‘natural by-products’’ of this field of study. Astakhov has pointed outthat the ultimate objective ofmetal cutting tribology is the optimization of the cutting process through minimizing the energy spent in metal cutting by considering all the physical and chemical processes that take place simultaneously inthis process[1].Increased tool life, improved integrity of the machined surface, higher process efficiency and stability are the results ofachievingthisgoal.Thestartingpointofsuchoptimizationistheconsideration ofenergypartitioninthe cuttingused for assessment ofphysical efficiency ofthe cutting system. Thelatter is defined asa ratio ofthe energy needed toseparateof the layer being removed from the rest of the workpiece and the total energy requiredbythecuttingsystemforitsexistenceprovidedthatthenominatorinsuch a ratio is minimized. 1.1.2 Tribology of Cutting Tools The tribology of cutting tools is defined as a part of metal cutting tribology that relates to the cutting tool itself, and thus used for its proper design and perfor- mance. Figure 1.1 shows the graphical representation of the cutting tool tribo- system.Geometry,mechanicsandphysicofsuchasystemaresystemicallyrelated 1 TribologyofCuttingTools 3 Fig.1.1 Graphical representationofcuttingtool tribologicalsystem so that it is improper to consider each of these groups of processes individually. Forexample,ifonechangesgeometryofthetoolrakefacebyaltering(restricting) thecontactlengthand/orrakeanglethenmaximumstressanditsdistributionover the tool chip interface change that, in turn, may change the contact temperature. Asaresult,thenatureoftribologicalprocessestaking placeonthisinterface may changesignificantlythat,inturn,mayaffectthecuttingtool,toolwearpatternand tool life. The main objective of the cutting tool tribology is to optimize the tribological conditions at the tool–chip and tool–workpiece interfaces. The understanding of these conditions and the proper utilization of this understanding in the design of cuttingtoolsshouldresultintheincreasedoverallefficiencyofthecuttingsystem and in the reduction of tool premature failures which is a crucial issue in modern unattendedproductionlinesandmanufacturingcells.Theseresults canbeusedin the meaningful selection of the machining regime, tool design including its geometry and tool materials (including coatings). 1.1.3 Importance of the Subject Recent survey indicates that in the automotive and mold-making industries: • The correct cutting tool geometry is selected less than 30 % of the time. • The tool is used at the rated cutting regime only 48 % of the time. • Only 57 % of the tools are used up to their full tool-life capability. • The correct tool material is selected less than 30 % of the time. • The correct cutting fluid (coolant) parameters are used 42 % of the time.