Novel Nanocoatings On Cutting Tools For Dry MachiningEPA Grant Number: R825339
Title: Novel Nanocoatings On Cutting Tools For Dry Machining
Investigators: Komanduri, Ranga , Kustas, Frank
Current Investigators: Komanduri, Ranga , Fehrenbacher, L.
Institution: Oklahoma State University - Main Campus , Technology Assessment & Transfer Inc
EPA Project Officer: Karn, Barbara
Project Period: October 1, 1996 through September 30, 1999
Project Amount: $180,000
RFA: Technology for a Sustainable Environment (1996) RFA Text | Recipients Lists
Research Category: Sustainability , Pollution Prevention/Sustainable Development
Description:This project is jointly funded by NSF and EPA. In this project we propose to investigate two novel technologies in an attempt to accomplish clean manufacturing. The development of new cutting tool materials based on novel multilayer nanocoating architectures of carbide/metal or solid lubricant/metal on cemented carbide tools by closed field unbalanced magnetron sputtering (CFUMS) process is the first novel technology. In contrast to the conventional Chemical Vapor Deposition (CVD) coating process, CFUMS process enables the production of exceptionally high quality, high density Physical Vapor Deposition (PVD) coatings. This is environmentally a clean process where no chemicals or harmful by-products are present unlike in CVD. The second novel technology is the use of the nanolayer coated tools in dry machining which makes it an environmentally friendly manufacturing.
Research tasks will be inducted separately for NSF and EPA. The research will concentrate on the hard and tough multilayer coatings (Class I) on cutting tools for dry machining for the NSF part and on low friction (tribological) coatings (Class II) on cutting tools for dry machining for the EPA part. Similarly research will be conducted on B4C/W, SiC/W,B4C/SiC (Class I) systems for the NSF and MoS2/Mo, WS2/W, and TaS2/Ta (Class II) systems for the EPA part. These coatings will be characterized by low angle x-ray diffraction, optical, SEM, AES, nanoindentation, and Rivet test for adhesion. The nature of coating will also be studied using an instrumented in situ SEM tribometer designed and built at OSU. The machining performance of these coated tools will be evaluated selectively in turning, milling, and drilling using instrumented set ups. Tool life and tool wear studies will be conducted over a range of cutting speeds using the characterization techniques proposed earlier. TA&T will deposit nanocoatings in consultation with OSU and characterize the physical and microstructural properties of the films produced. OSU will conduct most of the cutting studies. TA&T will also send some tools to potential users for evaluation.