S.C. Veldhuis

Hierarchical adaptive nanostructured PVD coatings for extreme tribological applications: the quest for nonequilibrium states and emergent behavior

Abstract Adaptive wear-resistant coatings produced by physical vapor deposition (PVD) are a relatively new generation of coatings which are attracting attention in the development of nanostructured materials for extreme tribological applications. An excellent example of such extreme operating conditions is high performance machining of hard-to-cut materials. The adaptive characteristics of such coatings develop fully during interaction with the severe environment. Modern adaptive coatings could be regarded as hierarchical surface-engineered nanostructural materials. They exhibit dynamic hierarchy on two major structural scales: (a) nanoscale surface layers of protective tribofilms generated during friction and (b) an underlying nano/microscaled layer. The tribofilms are responsible for some critical nanoscale effects that strongly impact the wear resistance of adaptive coatings. A new direction in nanomaterial research is discussed: compositional and microstructural optimization of the dynamically regenerating nanoscaled tribofilms on the surface of the adaptive coatings during friction. In this review we demonstrate the correlation between the microstructure, physical, chemical and micromechanical properties of hard coatings in their dynamic interaction (adaptation) with environment and the involvement of complex natural processes associated with self-organization during friction. Major physical, chemical and mechanical characteristics of the adaptive coating, which play a significant role in its operating properties, such as enhanced mass transfer, and the ability of the layer to provide dissipation and accumulation of frictional energy during operation are presented as well. Strategies for adaptive nanostructural coating design that enhance beneficial natural processes are outlined. The coatings exhibit emergent behavior during operation when their improved features work as a whole. In this way, as higher-ordered systems, they achieve multifunctionality and high wear resistance under extreme tribological conditions.

Modelling geometric and thermal errors in a five-axis cnc machine tool

Abstract The total volumetric error within the workspace of a machine tool is induced by the propagation of both scalar and position dependent geometrical errors, as well as time-variant thermal errors. This paper presents a compact volumetric error model which can be used as a basis for a practical compensation scheme. The broad objective is to increase the achievable accuracy of an industrial five-axis CNC machine tool. In place of using Denavit-Hartenberg (D-H) transformations, the method used here directly considers the shape and joint transformations for inaccurate links and joints using small angle approximations and then finds the total volumetric error in the workspace as a function of all the possible errors. The development of the model shows that angular deviations are independent of translational errors. However, the tool point deviations are dependent on both translational and rotational errors. The model has been used for the design and testing of a compensation strategy. The simulation studies indicate that CNC compensation for errors in X , Y and Z axes is possible. However, the capability of the CNC compensation for pitch, roll and yaw errors is dependent on the positioning of the rotary axes on the machine tool. This is shown by an example using the compensation scheme developed.

A Strategy for the Compensation of Errors in Five-Axis Machining

This paper outlines a strategy for error compensation in five-axis machining. The strategy uses a neural network model for compensation of errors due to changes in temperature and axis motion. Long term errors due to wear will be addressed with an adaptive approach. A method based on the analysis of the neural network weights is used for selecting the most relevant thermocouple inputs. Preliminary results show the strategy to be capable of holding the error to within 0.020 mm in the Z direction and 0.002° in the θX direction. Similar results are obtained during a cutting test.

Nanocrystalline coating design for extreme applications based on the concept of complex adaptive behavior

The development of effective hard coatings for high performance dry machining, which is associated with high stress/temperatures during friction, is a major challenge. Newly developed synergistically alloyed nanocrystalline adaptive Ti0.2Al0.55Cr0.2Si0.03Y0.02N plasma vapor deposited hard coatings exhibit excellent tool life under conditions of high performance dry machining of hardened steel, especially under severe and extreme cutting conditions. The coating is capable of sustaining cutting speeds as high as 600 m/min. Comprehensive investigation of the microstructure and properties of the coating was performed. The structure of the coating before and after service has been characterized by high resolution transmission electron microscopy. Micromechanical characteristics of the coating have been investigated at elevated temperatures. Oxidation resistance of the coating has been studied by using thermogravimetry within a temperature range of 25–1100 °C in air. The coefficient of friction of the coatings ...

Isoparametric line sampling for the inspection planning of sculptured surfaces

Abstract This paper presents a new approach for the sampling of sculptured surfaces using continuous scanning coordinate measuring machine probe heads. This approach is based on scanning isoparametric lines on the sculptured surface. This paper addresses the issue of isoparametric line sampling. The problem is to determine the locations of the sample lines extracted from the surface CAD model. These lines are fitted to construct a substitute geometry of the surface. The accuracy of the sampling plan is characterised by the maximum deviation between the substitute geometry and the surface CAD model. Two new algorithms for sampling isoparametric lines are proposed. These are, automatic sampling, and surface curvature-based sampling. Both algorithms are constrained by the maximum number of scan lines, and the step over distance between subsequent sample lines. Automatic sampling uses the deviations between the substitute geometry, and the surface CAD model to determine the sample locations. Curvature change-based sampling uses the change in surface curvature to determine the sampling line locations. Both algorithms are compared to uniform iso-planar sampling. The algorithms, their implementation, and a case study are presented in this paper.

Features of self-organization in ion modified nanocrystalline plasma vapor deposited AlTiN coatings under severe tribological conditions

Features of self-organization in the hard AlTiN plasma vapor deposited (PVD) coatings have been investigated under severe frictional conditions associated with high temperatures and stresses, which are typical for high-speed cutting. Aluminum-rich (around 67at.%) (Al67Ti33)N hard PVD coating has been modified by means of the “duplex” post-treatment, including annealing in vacuum at 700°C with subsequent ion implantation by Ar+. Structure modification of the surface layer has been studied using x-ray photoelectron spectroscopy, electron energy loss fine structure, and high resolution electron energy loss spectroscopy methods. Micromechanical characteristics of the coating have been studied using the nanoindentation method. Coefficient of friction was measured in relation to temperature. Wear behavior of the coating has been investigated under severe conditions of HSC of 1040 steel. Results show that the enhancement of nonequilibrium processes during friction due to ion implantation of AlTiN coating by Ar+ ...

Mechanism of adaptability for the nano-structured TiAlCrSiYN-based hard physical vapor deposition coatings under extreme frictional conditions

Recently, a family of hard mono- and multilayer TiAlCrSiYN-based coatings have been introduced that exhibit adaptive behavior under extreme tribological conditions (in particular during dry ultrahigh speed machining of hardened tool steels). The major feature of these coatings is the formation of the tribo-films on the friction surface which possess high protective ability under operating temperatures of 1000 °C and above. These tribo-films are generated as a result of a self-organization process during friction. But the mechanism how these films affect adaptability of the hard coating is still an open question. The major mechanism proposed in this paper is associated with a strong gradient of temperatures within the layer of nano-scaled tribo-films. This trend was outlined by the performed thermodynamic analysis of friction phenomena combined with the developing of a numerical model of heat transfer within cutting zone based on the finite element method. The results of the theoretical studies show that t...

Self-Organization during Friction in Complex Surface Engineered Tribosystems

Self-organization during friction in complex surface engineered tribosystems is investigated. The probability of self-organization in these complex tribosystems is studied on the basis of the theoretical concepts of irreversible thermodynamics. It is shown that a higher number of interrelated processes within the system result in an increased probability of self-organization. The results of this thermodynamic model are confirmed by the investigation of the wear performance of a novel Ti0.2Al0.55Cr0.2Si0.03Y0.02N/Ti0.25Al0.65Cr0.1N (PVD) coating with complex nano-multilayered structure under extreme tribological conditions of dry high-speed end milling of hardened H13 tool steel.

CAD-based sampling for CMM inspection of models with sculptured features

This paper addresses sampling models for trimmed sculptured surfaces, and multiple patches with boundary conditions. A CAD-based sampling system is developed and implemented in this work. The sculptured features are sampled along their isoparametric curves. These curves are then used to re-construct the model geometry using the skinning of cross section curves. We refer to the re-constructed model as the substitute geometry. The problem is to determine the sample curve locations such that the substitute geometry satisfies certain geometric conditions. These are, the form error, and the continuity of the substitute geometry across the boundaries of adjacent surfaces. Three criteria are integrated to determine the sample locations: the surface curvature change, the substitute geometry deviation from the CAD model, and the significance of trimmed portions of the surface. A boundary representation-based methodology for the sampling of trimmed surfaces is developed and implemented. This methodology is extended to handle n-sided surfaces obtained through filling n-sided regions with quadrilateral surface patches, and models that may include multiple surface patches. Furthermore, a tool to assess the sampling plans based on the continuity of the substitute geometry across boundaries of adjacent surface patches is developed. The developed algorithms, their implementations, and case studies are presented in this paper.

Why can TiAlCrSiYN-based adaptive coatings deliver exceptional performance under extreme frictional conditions?

Adaptive TiAlCrSiYN-based coatings show promise under the extreme tribological conditions of dry ultra-high-speed (500-700 m min-1) machining of hardened tool steels. During high speed machining, protective sapphire and mullite-like tribo-films form on the surface of TiAlCrSiYN-based coatings resulting in beneficial heat-redistribution in the cutting zone. XRD and HRTEM data show that the tribo-films act as a thermal barrier creating a strong thermal gradient. The data are consistent with the temperature decreasing from approximately 1100-1200 degrees C at the outer surface to approximately 600 degrees C at the tribo-film/coating interface. The mechanical properties of the multilayer TiAICrSiYN/TiA1CrN coating were measured by high temperature nanoindentation. It retains relatively high hardness (21 GPa) at 600 degrees C. The nanomechanical properties of the underlying coating layer provide a stable low wear environment for the tribo-films to form and regenerate so it can sustain high temperatures under operation (600 degrees C). This combination of characteristics explains the high wear resistance of the multilayer TiAlCrSiYN/TiAICrN coating under extreme operating conditions. TiAlCrSiYN and TiAlCrN monolayer coatings have a less effective combination of adaptability and mechanical characteristics and therefore lower tool life. The microstructural reasons for different optimum hardness and plasticity between monolayer and multilayer coatings are discussed.