Novel design and composition optimization of self-lubricating functionally graded cemented tungsten carbide cutting tool material for dry machining

Abstract

The functionally graded cemented tungsten carbide (FGCC) is a suitable material choice for cutting tool applications due to balanced hardness and fracture toughness. The presence of cobalt and CaF₂ composition gradient in FGCC may enhance mechanical as well as antifriction properties. Therefore, structural design of self-lubricating FGCC was proposed using Power law composition gradient model and thermal residual stresses (TRSs) as a key parameter. Wherein, S. Suresh and A. Mortensen model was adopted for estimation of TRS, and optimum composition gradient was identified at Power law exponent n = 2. The designed material displayed compressive and tensile TRS at surface and core respectively; subsequently fabricated by spark plasma sintering and characterized via scanning electron microscope (SEM), indentation method. The agreement between experimental and analytical values of TRS demonstrated the effectiveness of intended design model in the composition optimization of self-lubricating FGCC. This work will be helpful in implementation of dry machining for clean and green manufacturing.

Keywords

Functionally graded cemented tungsten carbide (FGCC) / Thermal residual stress (TRS) / Solid lubricant / Power law

References

[1] Zhang FL, Wang CY, Zhu M. Nanostructured WC / Co composite powder prepared by high energy ball milling. Scr Mater, 2003, 49: 1123-1128.

[2] Xu CH, Wu GY, Xiao GC, et al. Al₂O₃/(W, Ti) C / CaF₂ multi-component graded self-lubricating ceramic cutting tool material. Int J Refract Met Hard Mater, 2014, 45: 125-129.

[3] Liu H, Xue Q. The tribological properties of TZP-graphite self-lubricating ceramics. Wear, 1996, 198: 143-149.

[4] Klocke F, Eisenblatter G. Dry cutting. Ann ClRP, 1997, 46(2): 519-526.

[5] Jianxin D, Tongkun C, Lili L. Self-lubricating behaviors of Al₂O₃ / TiB₂ ceramic tools in dry high-speed machining of hardened steel. J Eur Ceram Soc, 2005, 25: 1073-1079.

[6] Sreejith PS, Ngoi BKA. Dry machining: machining of the future. J Mater Process Technol, 2000, 101: 287-291.

[7] Feng Y, Zhang J, Wang L, et al. Fabrication techniques and cutting performance of micro-textured self lubricating ceramic cutting tools by in-situ forming of Al₂O₃-TiC. Int J Refract Met Hard Mater, 2017, 68: 121-129.

[8] Wu G, Xua C, Xiao G, et al. Structure design of Al₂O₃/TiC/CaF₂ multicomponent gradient selflubricating ceramic composite and its tribological behaviors. Ceram Int, 2018, 44: 5550-5563.

[9] Gong F, Zhao J, Li Z, et al. Design, fabrication and mechanical properties of multidimensional graded ceramic tool materials. Ceram Int, 2018, 44: 2941-2951.

[10] Muthuraja A, Senthilvelan S. Adhesive wear performance of tungsten carbide based solid lubricant material. Int J Refract Met Hard Mater, 2015, 52: 235-244.

[11] Muthuraja A, Senthilvelan S. Abrasive wear performance of tungsten carbide based self-lubricant cutting tool material. Int J Refract Met Hard Mater, 2015, 51: 91-101.

[12] Singh T, Gangil B, Patnaik A, et al. Physico-mechanical, thermal and dynamic mechanical behaviour of natural-synthetic fiber reinforced vinylester based homogenous and functionally graded composites. Mater Res Express, 2019, 6: 025704.

[13] Abedi T, Khameneh Asl S. Synthesis of a novel functionally graded coatings of Ni-Cr/Al₂O₃ nanocomposite coating by pulse electrodeposition. Mater Res Express, 2019, 6: 056403.

[14] Xu C, Xiao G, Zhang Y, et al. Finite element design and fabrication of Al₂O₃/TiC/CaF₂ gradient self-lubricating ceramic tool material. Ceram Int, 2014, 40: 10971-10983.

[15] Xing A, Jun Z, Huang CZ, et al. Development of an advanced ceramic tool material—functionally gradient cutting ceramics. Mater Sci Eng A, 1998, 248: 125-131.

[16] Muthuraja A, Senthilvelan S. Development of tungsten carbide based self lubricant cutting tool material: preliminary investigation. Int J Refract Met Hard Mater, 2015, 48: 89-96.

[17] Deng JX, Liu LL, Yang XF, et al. Self-lubrication of Al2O3/TiC/CaF2 ceramic composites in sliding wear tests and in machining processes. Mater Des, 2007, 28: 757-764.

[18] Parihar RS, Setti SG, Sahu RK. Preliminary investigation on development of functionally graded cemented tungsten carbide with solid lubricant via ball milling and spark plasma sintering. J Compos Mater, 2018, 52(10): 1363-1377.

[19] Parihar RS, Setti SG, Sahu RK. Recent advances in the manufacturing processes of functionally graded materials: a review. Sci Eng Compos Mater, 2018, 25(2): 309-336.

[20] Kumar B, Mer KKS, Prasad L. Dry sliding wear behaviour of aluminium metal matrix-based functionally graded materials reinforced with alumina particles. Trends Mater Eng, 2019.

[21] Chen Z, Ji L, Guo N, Guo R. Mechanical properties and microstructure of Al₂O₃/TiC based self lubricating ceramic tool with CaF₂@Al (HO)₃. Int J Refract Met Hard Mater, 2018, 75: 50-55.

[22] Zhao J, Ai X, Deng J, et al. Thermal shock behaviors of functionally graded ceramic tool materials. J Eur Ceram Soc, 2004, 24: 847-854.

[23] Suresh S, Mortensen A. Functionally graded metals and metal-ceramic composites: part 2 thermomechanical behaviour. Int Mater Rev, 1997, 42(3): 85-116.

[24] Safari-Kahnaki A, Hosseini SM, Tahani M. Thermal shock analysis and thermo-elastic stress waves in functionally graded thick hollow cylinders using analytical method. Int J Mech Mater Des, 2011, 7: 167-184.

[25] Parihar RS, Setti SG, Sahu RK. Effect of sintering parameters on microstructure and mechanical properties of self-lubricating functionally graded cemented tungsten carbide. J Manuf Processes, 2019, 45: 498-508.

[26] Emanuelli L, Molinari A, Arrighetti G, et al. Effect of the sintering parameters on the liquid Co migration in WC-Co. Int J Refract Met Hard Mater, 2018, 70: 202-209.

[27] Ther O, Colin C, Dourfaye A. Functionally graded cemented carbides elaboration by imbibition process—better understanding of liquid migration and homogenization mechanisms for an improved process. Front Mater Process Appl Res Technol, 2017.

[28] Larsson C, Oden M. X-ray diffraction determination of residual stresses in functionally graded WC-Co composites. Int J Refract Met Hard Mater, 2004, 22: 177-184.

Funding

Chhattisgarh Council of Science and Technology (CCOST)(2230/CCOST/MRP/15)