Machining with Nanomaterials (eBook)

Professor Mark J. Jackson, PhD, PD, is the McCune and Middlekauff Foundation Endowed Professor and Academic Department Head at Kansas State University. He has also served as General Chairman of the International Surface Engineering Congress and is Deputy President of the World Academy of Materials and Manufacturing Engineering. Dr. Jackson has also directed, co-directed, and managed research grants, including those funded by The Royal Academy of Engineering (London), Ministry of Defense (London), Atomic Weapons Research Establishment, National Science Foundation, N.A.S.A., and the U.S. Department of Energy, among others. He has organized many conferences and has authored and co-authored over 250 publications in archived journals and refereed conference proceedings and has written and edited books in the area of nanotechnology and manufacturing.Dr. Jonathan S. Morrell, PhD, is a senior chemist and technical manager at the Y-12 National Security Complex in Oak Ridge, Tennessee, and has led the Compatibility and Surveillance Section of the Development Division since 2005. Dr. Morrell currently serves on several coordinated research projects at the International Atomic Energy Agency (IAEA) in Vienna, Austria on lifetime extension of aging research reactors. He is also an adjunct faculty professor in the Department of Chemistry at the University of Tennessee and in the Natural and Behavioral Science Department at Pellissippi State Community College in Knoxville. Dr. Morrell has ten issued patents, authored and co-authored more than 32 publications in archived journals and refereed conference proceedings, authored over 110 formal reports and edited four technical books. He is currently a member of the editorial boards of the International Journal of Molecular Engineering, International Journal of Nano and Biomaterials, and International Journal of Nanoparticles.

Preface 6
Contents 8
About the Editors 10
Chapter 1: Fundamentals of Machining 13
1.1 Introduction: Machining Effects 13
1.1.1 Prediction of friction power Angle 17
1.1.2 Plastic Behavior at Large Strains 22
1.1.3 Langford and Cohen´s Model 22
1.1.4 Walker and Shaw´s Model 23
1.1.5 Usui´s Model 24
1.1.6 Saw Tooth Chip Formation 25
1.1.7 Fluid-Like Flow in Chip Formation 26
1.2 Size Effects in Micromachining 26
1.3 Nanomachining 27
1.3.1 Nanometric Machining 28
1.3.2 Theoretical Basis of Nanomachining 29
1.3.2.1 Cutting Force and Energy 29
1.3.2.2 Cutting Temperatures 31
1.3.2.3 Chip Formation 33
1.3.2.4 Minimum Undeformed Chip Thickness 35
1.3.2.5 Critical Cutting Radius 36
1.3.2.6 Workpiece Materials 37
1.3.3 Comparison of Nanometric Machining and Conventional Machining 39
1.4 Recent Developments in Machining Simulations 40
1.4.1 Complete 3D Surface Machining Simulation 40
1.4.2 Consideration of Fluids in MD Cutting Simulation 41
References 45
Chapter 2: Machining Stability 48
2.1 Introduction 48
2.2 Phase Difference and Machining Stability: A Physical Interpretation 50
2.3 Sensitivity Analysis of the Phase Difference of Machining Chatter 52
2.4 Verification of the Stability Criterion 56
2.5 Conclusions 63
Derivation of the Stability Criterion with the Phase Difference Sensitivity 63
References 65
Chapter 3: Machining Chatter Suppression 66
3.1 Introduction 66
3.2 Nonlinear Machining Chatter Model 69
3.3 Characteristic Equation of SSV Cutting 70
3.3.1 Equivalently Linearized Differential Equation 70
3.3.2 Time Delay of SSV Cutting 71
3.3.3 Characteristic Equation 72
3.4 Stability Increment by SSV Cutting 73
3.5 Determination of Stability Increment Index 75
3.6 Selecting SSV Amplitude from Energy Analysis 77
3.6.1 Preliminary Procedure of Selecting SSV Amplitudes 78
3.6.2 Bessel Function Values and Their Profile Curves 79
3.6.3 Selecting SSV Amplitude 81
3.6.3.1 Industrial Example 81
3.7 Conclusions 82
References 85
Chapter 4: Micromachining from a Materials Perspective 87
4.1 Machining Theory 87
4.2 High-Speed Machining 95
4.3 Cutting Tool Wear 102
4.4 Tool Coatings 109
4.5 Micromachining 124
4.6 Research Directions 132
References 133
Chapter 5: Machining of Brittle Materials Using Nanostructured Diamond Tools 138
5.1 Introduction 138
5.2 Mechanisms of Tool Wear 139
5.3 Machining Simulations 143
5.4 Experimental Methods 147
5.5 Experimental Results and Discussion 154
5.5.1 Film Characterization 154
5.5.2 Wear Mechanisms 156
5.5.2.1 Crater Wear and Notching Wear 156
5.5.2.2 Flank Wear 157
5.5.2.3 Cutting Forces and Friction Coefficient 160
5.6 Conclusions 161
References 162
Chapter 6: Analysis of Contact of Chip and Tool Using Nanostructured Coated Cutting Tools 163
6.1 Introduction 163
6.2 Computational Analysis of Machining Conditions 164
6.2.1 Loewen and Shaw´s Method to Calculating Cutting Temperatures 164
6.3 Finite Element Studies of Machining Conditions 175
6.4 Discussion 177
6.5 Conclusions 181
References 182
Chapter 7: Economic Analysis of Machining with Nanostructured Coatings 184
7.1 Introduction 184
7.2 Experimental Apparatus 188
7.3 Experimental Results 188
7.3.1 Cutting Tool Wear 188
7.3.2 Volume Removed as a Function of Flank Wear 191
7.3.3 Summary of Experimental Results 193
7.4 Cutting Tool Life 195
7.4.1 Determination of Exponents 196
7.4.2 Determination of the Constant 199
7.5 Economic Analysis 200
7.6 Discussion 202
7.7 Conclusions 206
References 206
Chapter 8: Analysis of Machining Hardened Steels Using Coated Cutting Tools 207
8.1 Introduction 207
8.2 Computational Understanding of Various Machining Conditions 208
8.2.1 Properties of D2 Tool Steel 208
8.2.2 Loewen and Shaw´s Method Applied to Calculating Temperature 208
8.3 Finite Element Studies of Machining Conditions 220
8.4 Discussion 223
8.5 Conclusions 234
References 235
Chapter 9: Modeling and Machining of Medical Materials 237
9.1 Introduction: Material Requirements for the Biomedical Industry 238
9.1.1 Properties of Titanium Alloys 239
9.1.2 Classification of Ti Alloys 240
9.1.3 Biomedical Applications of Ti Alloys 244
9.2 Material Models 244
9.2.1 Johnson-Cook Model (J-C) 245
9.2.2 Mechanical Threshold Model (MTS) 246
9.2.3 Power Law Model 247
9.2.4 Zerilli and Armstrong Model 247
9.2.5 Japanese Model 248
9.2.6 Bammann, Chiesa, and Johnson Model 248
9.2.7 The Applied Model 249
9.3 Machining of Titanium Alloys 251
9.3.1 Micro-milling 259
9.3.1.1 The Size Effect 260
9.3.1.2 Minimum Chip Thickness 264
9.3.1.3 Computational Analysis 267
9.4 Conclusions 274
References 274
Chapter 10: Manufacture and Development of Nanostructured Diamond Tools 278
10.1 Introduction 278
10.2 Analysis of Stress in a Loaded Wedge 280
10.3 Stress Analysis in a Wedge with a Distributed Load 286
10.3.1 Development of Wear Model 289
10.3.2 Computational Stress Analysis of Single Diamond Grains 290
10.4 Experimental Methods 292
10.4.1 Hot Filament CVD 292
10.4.2 Measurement of Wear of Diamond Tools 293
10.5 Discussion 294
10.5.1 Diamond Deposition 294
10.5.2 Wear of Diamonds 298
10.6 Conclusions 301
References 302
Chapter 11: Comparison of Original and Re-coated Cutting Tools Machining Steel 304
11.1 Introduction 304
11.2 Experimental Methods 306
11.2.1 Materials 306
11.2.2 Cutting Tools 307
11.2.3 Machining Center 307
11.2.4 Cutting Fluid 309
11.2.5 Experimental Strategy 310
11.3 Experimental Results and Discussions 313
11.3.1 Tool Wear 313
11.3.1.1 TiAlN Coated Drills 313
11.3.1.2 AlCrN Coated Drills 315
11.3.2 Thrust Force and Torque 317
11.3.2.1 TiAlN Coated Drills 317
11.3.2.2 AlCrN Coated Drills 321
11.3.2.3 Comparison Between Coatings 322
11.4 Conclusions 324
References 325
Chapter 12: Multi-objective Optimization of Cutting Conditions When Turning Aluminum Alloys (1350-O and 7075-T6 Grades) Using ... 327
12.1 Introduction 328
12.2 Experimental 330
12.2.1 Microstructure and Mechanical Properties of the Aluminum Alloys 330
12.2.2 Machining Operations 331
12.2.3 The CCD Treatment 332
12.3 Results and Discussion 332
12.3.1 Microstructure of Types 1350-O and 7075-T6 Aluminum Alloy 332
12.3.2 Hardness and Tensile Test Data of Types 1350-O and 7075-T6 Aluminum Alloys 333
12.3.3 The CCD Machining Test Data and Regression Analysis 333
12.3.4 Chip Characteristics and Chip Thickness Ratio: CTR Results 336
12.3.5 Genetic Algorithm Multi-objective (Fu and CTR) Optimization for Types 1350-O and 7075-T6 Aluminum Alloy 338
12.3.6 Validation of the Method 339
12.3.7 Surface Responses and Level Curves of the Machining Force and Chip Thickness Ratio Models 341
12.4 Conclusions 347
References 348
Chapter 13: Nanogrinding with Abrasives 351
13.1 Introduction 351
13.2 Nanogrinding with Coated Piezoelectric Materials 352
13.3 Practical Nanogrinding 354
13.3.1 Nanogrinding Machine 354
13.3.2 Nanogrinding Procedure 355
13.3.3 Nanogrinding Results 357
13.4 Laser Texturing of Abrasive Materials 359
13.4.1 Texturing Procedure 361
13.4.1.1 Measurement of Texturing Temperature 361
13.4.1.2 Orientation Imaging Microscopy 361
13.4.1.3 Nanogrinding Practice 362
13.4.2 Experimental Results and Discussion 363
13.4.2.1 Laser Texturing Temperature 363
13.4.2.2 Orientation Imaging Microscopy of Laser-Dressed Materials 367
13.4.2.3 Nanogrinding Practice 369
13.5 Discussion 371
References 372
Index 374