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New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: closed (10 September 2023) | Viewed by 18835

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Special Issue Editors

Prof. Dr. Bing Guo

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Guest Editor

Center for Precision Engineering, School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
Interests: precision and ultraprecision machining; microstructured surface tools; grinding tools; robot-assisted machining; laser micromachining

Dr. Quanli Zhang

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Guest Editor

College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: high-efficiency precision machining; design and fabrication of grinding tools; laser-assisted machining; surface modification and strengthening

Dr. Zhiqiang Liang

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Guest Editor

School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
Interests: precision and ultra-precision grinding; cutting of difficult-to-cut materials; design and fabrication of micro-tools and machine tools
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Special Issue Information

Dear Colleagues,

The application of coatings and surface treatments to cutting and grinding tools has provided substantial benefits to turning, milling, drilling, boring, grinding, lapping, polishing and other mechanical process. The constant development of coatings and surface treatment technologies for cutting and grinding tools render them more resistant to heat, corrosion, wear, breakage, loading, chip welding, and a host of other complications. These processes facilitate force reduction, chatter suppression, accuracy maintain, subsurface damage decrease, energy conservation, emission reduction and other new features for machining process. Therefore, due to the increasing demands of the industry, increasing attention has been paid to coatings and surface treatments in recent decades, with the aim of enhancing the machining performance of cutting and grinding tools.

This Special Issue of Materials intends to provide a forum for original research articles as well as review articles on current advances in the field of tool coatings and surface treatments for machining applications. Areas of interest include but are not limited to advanced nitride, carbide, oxide, diamond-like, composite and nano coatings, and ion implantation, texture modification, bionic processing, wheel truing/dressing and other surface treatments that are adopted for tools during machining applications. Aspects of research of interest include investigations of advanced coatings, deposition methods, surface design, treatment process, surface characteristic testing, tool performance and wear property evaluation, machining studies, simulation and applications.

Prof. Dr. Bing Guo
Dr. Quanli Zhang
Dr. Zhiqiang Liang
Guest Editors

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Keywords

coating
surface treatment
surface modification
cutting tool
grinding tool
fabrication process
surface characteristic
tool performance
wear property
application

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Published Papers (9 papers)

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Research

12 pages, 6129 KiB

Open AccessArticle

Modeling of Rapid Response Characteristics of Piezoelectric Actuators for Ultra-Precision Machining

by Bowen Zhong, Zhan Liao, Xi Zhang, Ziqi Jin and Lining Sun

Materials 2023, 16(6), 2272; https://doi.org/10.3390/ma16062272 - 11 Mar 2023

Cited by 3 | Viewed by 1705

Abstract

Piezoelectric actuators are characterized by high positioning accuracy, high stiffness and a fast response and are widely used in ultra-precision machining technologies such as fast tool servo technology and ultrasonic machining. The rapid response characteristics of piezoelectric actuators often determine the overall quality of machining. However, there has been little research on the fast response characteristics of piezoelectric actuators, and this knowledge gap will lead to low precision and poor quality of the final machining. The fast response characteristics of a piezoelectric actuator were studied in this work. Firstly, the piezoelectric actuator was divided into a no-load state and a load state according to the working state. A fast response analysis and output characteristic analysis were carried out, the corresponding dynamic model was established, and then the model was simulated. Finally, an experimental system was established to verify the dynamic model of the piezoelectric actuator’s fast response by conducting an experiment in which the piezoelectric actuator bounces a steel ball. The experimental results verify the correctness of the model and show that the greater the cross-sectional area and height of the piezoelectric actuator, the higher the bouncing height of the ball, and the better the dynamic performance of the piezoelectric actuator. It is believed that this study has guiding significance for the application of the dynamic characteristics of piezoelectric actuators in the machining field. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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17 pages, 13337 KiB

Open AccessArticle

A Novel Feedforward Model of Piezoelectric Actuator for Precision Rapid Cutting

by Bowen Zhong, Shilin Liu, Chenjun Wang, Ziqi Jin and Lining Sun

Materials 2023, 16(6), 2271; https://doi.org/10.3390/ma16062271 - 11 Mar 2023

Cited by 4 | Viewed by 1543

Abstract

The piezoelectric actuator has been widely used in modern precision cutting technology due to its fast response speed and high positioning accuracy. In recent years, with the development of precision technology, modern cutting requires higher and higher cutting accuracy and efficiency. Therefore, this paper proposes a feedforward control method based on the modified Bouc–Wen (MBW) model. Firstly, a novel asymmetrical modified Bouc–Wen model with an innovative form of shape control function is developed to model the hysteresis nonlinearity property of piezoelectric actuators. Then, a self-adaptive cooperative particle swarm optimization (PSO) algorithm is developed to identify the parameters of MBW model. The comparative evaluation reveals that the MBW model outperforms the classical Bouc–Wen (CBW) model by 66.4% in modeling accuracy. Compared with traditional PSO algorithm, the self-adaptive cooperative PSO algorithm can obtain minimum fitness in parameter identification. Furthermore, the feedforward control strategy is realized to improve the position tracking accuracy. A position tracking experiment verifies that the feedforward control strategy improves the tracking accuracy of piezoelectric actuators significantly compared with the open-loop control strategy. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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29 pages, 4591 KiB

Open AccessArticle

Application of Integrated BWM Fuzzy-MARCOS Approach for Coating Material Selection in Tooling Industries

by Sunil Kumar, Shubrajit Bhaumik, Lokeswar Patnaik, Saikat Ranjan Maity and Viorel Paleu

Materials 2022, 15(24), 9002; https://doi.org/10.3390/ma15249002 - 16 Dec 2022

Cited by 7 | Viewed by 2319

Abstract

The life of metal forming dies and the efficiency of tooling industries depends on the mechanical and wear properties of tool steel. These properties can be further improved by depositing the ceramic coating on heat-treated tool steel. Numerous coating materials with various excellent features are already available commercially; however, the selection of the best coating material is still an immense challenge for users. Compared to various studies related to material selection problems in the contrasting area of utilization, remarkably, little research work has been done in tooling industries. In the present work, we have identified eight coating materials (alternatives) and nine evaluation criteria under the consultation of an expert in the tooling application and tribological field. To deal with this coating material selection problem, an integrated fuzzy-multi attributed decision-making method is proposed which comprises best worst method and fuzzy-Measurement Alternatives and Ranking according to the Compromise Solution method. This integrated fuzzy- multi attributed decision-making method is used to evaluate the alternatives, and the obtained results were scrutinized via utilizing various sensitivity analysis procedures. In the first phase of analysis, seven scenarios of criteria weight change were used, which was derived by the best-worst method; dynamic matrices are used in the second phase of analysis. In the third and fourth phases, obtained ranks were compared with those obtained by different weight calculation methods and ranking methods, respectively. In the present study, AlCrN/TiAlN coating (alternative Cm₅) was found to be the best coating material based on the results obtained after sensitivity analysis. Further, in this study, we have proposed a novel method that helps to solve the coating material selection problem or any kind of selection complications. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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14 pages, 3867 KiB

Open AccessArticle

High-Speed Dicing of SiC Wafers with 0.048 mm Diamond Blades via Rolling-Slitting

by Yuanru Feng, Kenan Li, Zhen Dou, Zhengwen Zhang and Bing Guo

Materials 2022, 15(22), 8083; https://doi.org/10.3390/ma15228083 - 15 Nov 2022

Cited by 10 | Viewed by 3262

Abstract

In this study, an innovative fabrication method called rolling-slitting forming, which forms ultra-thin diamond blades, was presented for the first time. Furthermore, the feasibility of the rolling-slitting forming method when applied to silicon carbide wafer dicing blades was investigated; moreover, the cold-pressing blade samples were manufactured through the conventional process under the same sintering conditions to compare and analyze the manufacturing efficiency, organization and performance. The results show that the new method achieves high-precision and low-thickness dicing blades through continuous production without molds—with the thinnest blades being 0.048 mm thick. Furthermore, the rolling-slitting blade has a unique multiporous heat-conductive matrix structure and in-situ generated amorphous pyrolytic carbon, which can reduce the dicing resistance and contribute to a better cutting quality. In addition, the effects of the dicing parameters on SiC were investigated by using indications of spindle current, dicing chipping size and kerf width during the high dicing process. For a dicing depth of 0.2 mm, the ideal performance of dicing SiC with an ultra-thin blade was achieved at a spindle speed of 22,000 rpm and a feed rate of 5 mm/s. This research provides a new idea for the manufacturing of dicing blades, which can satisfy the demand for ultra-narrow dicing streets of high integration of ICs. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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12 pages, 4555 KiB

Open AccessArticle

Cross-Sectional Profile Evolution of Cu-Ti Gradient Films on C17200 Cu by Vacuum Thermal Diffusion

by Yandan Zhu, Zecheng Li, Hongchao Bi, Qilong Shi, Yujun Han and Quanli Zhang

Materials 2022, 15(22), 8002; https://doi.org/10.3390/ma15228002 - 12 Nov 2022

Cited by 1 | Viewed by 1429

Abstract

To improve the wear resistance and fatigue life of Cu alloys, surface modification by combining the magnetron sputtering of Ti film followed by vacuum thermal diffusion is always applied, where the structure and composition of the fabricated film play a determinant role on the mechanical properties. In the present work, the evolution of the layered structure and the element distribution of the formed multi-phases coating on C17200 Cu alloy are investigated by mathematical calculation based on Fick’s law, and the experimental verification by the thermal diffusion of the gradient Cu-Ti film was undertaken under different temperatures and durations. The results show that the layered structure of the fabricated coating is dependent on the Cu-Ti atom concentration, the increasing time and the temperature, where a single or stratified layer is formed due to the generated Cu-Ti intermetallics for the inter-diffusion between the Cu and Ti atoms. The atom distribution by the proposed simulation method based on Fick’s law corresponds to the experimental results, which can be applied to designing the structure of the modification layer. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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14 pages, 5817 KiB

Open AccessArticle

Experimental Study on Laser Ablation Texture-Assisted Grinding of Tungsten Alloy

by Bing Chen, Ye Guo, Shunshun Li and Guoyue Liu

Materials 2022, 15(19), 7028; https://doi.org/10.3390/ma15197028 - 10 Oct 2022

Cited by 7 | Viewed by 1760

Abstract

In order to machine the tungsten alloy with high efficiency, low damage and precision, laser ablation texture technology and precision grinding technology were combined to carry out grinding experiments of tungsten alloy and laser ablation texture-assisted grinding experiments. The advantages of laser ablation texture-assisted grinding tungsten alloy were investigated by comparing of the surface morphology, grinding force and surface roughness between ordinary grinding and laser ablative texture-assisted grinding. The results demonstrate that the surface morphology of ordinary grinding tungsten alloy was poor, the surface roughness was relatively high and the grinding force was relatively large. The surface morphology of the laser ablation texture-assisted grinding tungsten alloy processed by laser ablation texture was improved, the surface roughness decreased by 0.023 µm–0.204 µm, the normal force decreased by 49.91–59.46% and the tangent force decreased by 44.11–58.49%. Meantime, for the area ratio of texture A being the most, the grinding effect was related to the area ratio of texture, and the lowest grinding force and the best surface quality were observed on the tungsten alloy with the laser ablated texture A; the grinding forces and roughness of the other textures’ workpiece was similar and close because of their similar area ratios. The results demonstrate that laser ablation texture-assisted grinding of tungsten alloy could improve machining quality and reduce grinding force, which would provide guidance for realizing the high efficiency and precision machining of tungsten alloy. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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12 pages, 7605 KiB

Open AccessArticle

Fractal Characteristic-Induced Optimization of the Fixed Abrasive Lapping Plate in Fabricating Bipolar Plate of Proton-Exchange Membrane Fuel Cells

by Guoqing Pan, Zhengwei Wang and Donghui Wen

Materials 2022, 15(17), 5922; https://doi.org/10.3390/ma15175922 - 26 Aug 2022

Viewed by 1510

Abstract

Purpose: A bipolar plate with fractal-characterized microstructures can realize intelligent energy transmission and obtain a high efficiency of proton-exchange membrane fuel cells. In this paper, fixed abrasive lapping technology is proposed to fabricate a surface microstructure on a bipolar plate with fractal characteristics. Methodology: The kinematics of the fixed abrasive lapping process was developed and employed to numerically investigate the particle trajectories moving on the target surface by considering the different arraying forms of diamonds on the lapping plate. Findings: It was found from an analysis of both the uniformity and the fractal characteristics that the arraying form of diamonds on the lapping plate, with the distribution of latitude and longitude with an angle of 30° and a gap of concentric circles of 40 mm with a minimum radius of 70 mm and maximum radius of 190 mm, can be used to obtain the best uniformity and fractal characteristics in the fixed abrasive lapping of a bipolar plate. Conclusions: The distribution of the latitude and longitude of 40° and 30° considered in this study is expected to realize the best machining performance in the bipolar plate and present good cell performance. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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18 pages, 10412 KiB

Open AccessArticle

Surface Quality Control Strategy of Aspherical Mold Based on Screw Feed Polishing of Small Polishing Tool

by Jiarong Zhang, Han Wang, Xiangyou Zhu, Honghui Yao, Shaomu Zhuo, Shuaijie Ma, Daohua Zhan and Nian Cai

Materials 2022, 15(14), 4848; https://doi.org/10.3390/ma15144848 - 12 Jul 2022

Cited by 4 | Viewed by 1673

Abstract

For small aspherical molds, it is difficult for the existing polishing method to take into account the correction of the surface error and the control of the uniformity of the surface roughness (SR) distribution, because the polishing tool is always larger than the small mold. Therefore, we used viscoelastic polyester fiber cloth to wrap the small steel ball as a polishing tool to adapt to the surface shape change of the aspherical mold, and designed a semi-flexible small polishing disc tool with microstructure, which can better adapt to the curvature change of aspherical surface and obtain better SR Ra. At the same time, a combined polishing method of constant speed and variable speed for screw feed was proposed to improve the uniformity of SR distribution in the paper. Then, a series of theoretical analysis and experimental verification were carried out in this paper to predict the tool influence function (TIF) of the two polishing tools and the effectiveness of the combined polishing method. In the experiment, a TIF bandwidth of about 0.46 mm was obtained with a small spherical polishing tool, which favors the surface shape correction of the small aspherical mold. The experiment of uniform removal with a small polishing disc tool was carried out to quickly reduce the Ra. Finally, the surface quality of the aspherical mold was effectively improved, combined with the constant speed and variable speed polishing modes of screw feed of the small spherical polishing tool and the smoothing effect of the small polishing disc tool. The peak valley (PV) of two small aspherical molds with an optical effective diameter less than 13 mm converged from 0.3572 μm and 0.2075 μm to 0.1282 μm and 0.071 μm, respectively. At the same time, the SR dispersion coefficient was reduced from 27.9% and 41.6% to 14.2% and 12.7%, respectively. The study provides a good solution for the surface quality control of small aspherical molds. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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14 pages, 5204 KiB

Open AccessArticle

Effects of Substrate Roughness on Microstructure and Fatigue Behavior of Plasma Electrolytic Oxidation-Coated Ti-6Al-4V Alloy

by Fangquan Xi, Yong Huang, Yahui Zhao, Yang Liu, Weibing Dai and Yanzhong Tian

Materials 2022, 15(12), 4256; https://doi.org/10.3390/ma15124256 - 15 Jun 2022

Cited by 7 | Viewed by 1853

Abstract

Ceramic coatings were prepared by plasma electrolytic oxidation (PEO) on four different surface roughness’ of Ti-6Al-4V alloys. The effects of substrate roughness on the microstructure and fatigue behavior were investigated. Microstructural characterization was carried out by scanning electron microscopy (SEM) and a laser scanning confocal microscope. In addition, an X-ray diffractometer (XRD) and a U-X360 stress meter were used to analyze the phase composition and residual stress properties of the coatings. The microstructure of coatings revealed the growth mechanism of the coatings. The larger and deeper grooves of the substrate promoted the nucleation and growth of the PEO coating, but the defects (cracks and pores) of the oxide layer became more serious. The fatigue test indicated a significant influence of substrate roughness on the fatigue life under low cyclic stress. The fatigue damage of PEO coatings decreases as the surface roughness of substrates decreases because of the synergistic effect of the coating surface defects and coating/substrate interface roughness. Substrate roughness influences the quality and fatigue performance of the oxide layer. Full article

(This article belongs to the Special Issue New Advances in Coatings and Surface Treatments for Cutting and Grinding Tools)

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