Friction behaviors in the metal cutting process:state of the art and future perspectives

Material removal in the cutting process is regarded as a friction system with multiple input and output variables.The complexity of the cutting friction system is caused by the extreme conditions existing on the tool–chip and tool–workpiece interfaces.The critical issue is significant to use knowledge of cutting friction behaviors to guide researchers and industrial manufacturing engineers in designing rational cutting processes to reduce tool wear and improve surface quality.This review focuses on the state of the art of research on friction behaviors in cutting procedures as well as future perspectives.First,the cutting friction phenomena under extreme conditions,such as high temperature,large strain/strain rates,sticking–sliding contact states,and diverse cutting conditions are analyzed.Second,the theoretical models of cutting friction behaviors and the application of simulation technology are discussed.Third,the factors that affect friction behaviors are analyzed,including material matching,cutting parameters,lubrication/cooling conditions,micro/nano surface textures,and tool coatings.Then,the consequences of the cutting friction phenomena,including tool wear patterns,tool life,chip formation,and the machined surface are analyzed.Finally,the research limitations and future work for cutting friction behaviors are discussed.This review contributes to the understanding of cutting friction behaviors and the development of high-quality cutting technology.

On the role of sliding friction effect in nonlinear tri-hybrid vibration-based energy harvesting

This work aims to develop an experimental investigation into the effectiveness of the sliding-mode approach for hybrid vibration-based energy harvesting.A proposed sliding-mode triboelectric-electromagnetic-piezoelectric energy harvesting model involves a cantilever beam with a tip mass exposed to magnetic and frictional forces.The experimental findings indicate that the system can achieve its peak inter-well oscillation output within a low-frequency range of 4 Hz–6 Hz.Friction has a lesser impact on the open-circuit voltage output at an excitation acceleration of 1.5g compared with 1g.The distribution of tri-stability changes with the presence of friction.This model provides a deeper understanding of the influence of the dry friction coefficient(0.2–0.5) on the interactive behaviors of different generator units.

Effects of friction stir processing and nano-hydroxyapatite on the microstructure,hardness,degradation rate and in-vitro bioactivity of WE43 alloy for biomedical applications

Nowadays,magnesium alloys are emerging in biomedical implants for their similar properties to natural bones.However,the rapid degradation of magnesium alloys in biological media hinders successful implantation.Refinement of microstructure,as well as reinforcement particles can significantly improve the degradation rate.In this work,multi-pass friction stir processing(FSP)was proposed to synthesize WE43/nano-hydroxyapatite(n HA)surface composite,the microstructure,reinforced particle distribution,micro-hardness,corrosion behavior and in-vitro bioactivity were studied.The subsequent FSP passes of WE43 alloy and WE43/n HA composite refined the grain size which was reduced by 94.29%and 95.92%(2.63 and 1.88μm,respectively)compared to base metal after three passes.This resulted in increasing the microhardness by 120%(90.86 HV0.1)and 135%(105.59 HV0.1)for the WE43 and WE43-n HA,respectively.It is found that increasing FSP passes improved the uniform distribution of n HA particles within the composite matrix which led to improved corrosion resistance and less degradation rate.The corrosion rate of the FSPed WE43/n HA composite after three passes was reduced by 38.2%(4.13 mm/year)and the degradation rate was reduced by 69.7%(2.87 mm/y).This is attributed to secondary phase(Mg24Y5and Mg41Nd5)particle fragmentation and redistribution,as well as a homogeneous distribution of n HA.Additionally,the growing Ca-P and Mg(OH)2layer formed on the surface represented a protective layer that reduced the degradation rate.The wettability test revealed a relatively hydrophilic surface with water contact angle of 49.1±2.2°compared to 71.2±2.1°for base metal.Also,biomineralization test showed that apatite layer grew after immersion 7d in simulated body fluid with atomic ratio of Ca/P 1.60 approaching the stoichiometric ratio(1.67)indicating superior bioactivity of FSPed WE43/n HA composite after three passes.These results raise that the grain refinement by FSP and introduction of n HA particles significantly improved the degradation rate and in-vitro bioactivity of WE43 alloy for biomedical applications.

3D modeling for effect of tool eccentricity on coupled thermal and material flow characteristics during friction stir welding

A novel three-dimensional numerical model is proposed to investigate the effect of tool eccentricity on the coupled thermal and material flow characteristics in friction stir welding(FSW) process.An asymmetrical boundary condition at the tool-workpiece interface,and the dynamic mesh technique are both employed for the consideration of the tool eccentricity during tool rotating.It is found that tool eccentricity induces the periodical variation of the heat densities both at the tool-workpiece interface and inside the shear layer,but the fluctuation amplitudes of the heat density variations are limited.However,it is demonstrated that tool eccentricity results in significant variation of the material flow behavior in one tool rotating period.Moreover,the material velocity variation at the retreating side is particularly important for the formation of the periodic characteristics in FSW.The modeling result is found to be in good agreement with the experimental one.

Friction Characteristics Between Marine Clay and Construction Materials

Structure-soil interface friction characteristics is of importance to investigate the interaction between engineering structures and soils,especially for offshore structures.The interface friction behavior between marine clay and structural materials with different roughness was studied in this paper by using 3D optical scanning tests,a modified direct shear device and numerical simulation.Relationships between the surface roughness of structures,water content and interface friction angle were presented by model tests.The increase of water contents decreased the interface friction angles.For interfaces with different roughness,the interface friction angles will be smaller than that of the soil when the water content exceeds a certain value.The roughness of the interface and the water content of the soil are mutually coupled to influence the coefficient of friction(COF).This paper proposed a Finite Element Method(FEM)to simulate the interface direct shear tests of structures with different roughness.The surface models with different roughness are established based on the structure data obtained by 3D scanning.The Coupled Eulerian-Lagrangian(CEL)approach was employed to analyse soils sheared by irregular surfaces.The interface behavior for interfaces with different roughness under cyclic shear stresses was analyzed by FEM.

Effects of pin geometry on the material flow behavior of friction stir spot welded 2A12 aluminum alloy

A three-dimensional finite volume model was established by the ANSYS FLUENT software to simulate the material flow behavior during the friction stir spot welding （FSSW） process. Effects of the full-threaded pin and the reverse-threaded pin on the material flow behavior were mainly discussed. Results showed that the biggest material flow velocity appeared at the outer edge of the tool shoulder. The velocity value became smaller with the increase of the distance away from the tool surface. In general, material flows downwards along the pin thread when the full-threaded pin is used. Meanwhile, both the materials of the upper and the lower plates flow towards the lap interface along the pin thread when the reverse-threaded pin is used. The numerical simulation results were investigated by experiment, in which 2A12 aluminum alloy was used as the research object. The effective sheet thickness （EST） and stir zone （SZ） width of the joint by the reverse-threaded pin were much bigger than those by the full-threaded pin. Accordingly, cross tension failure load of the joint by the reverse-threaded pin is 23% bigger than the joint by the full-threaded pin.

Deformation behaviors of 21-6-9 stainless steel tube numerical control bending under different friction conditions

For contact dominated numerical control(NC) bending process of tube, the effect of friction on bending deformation behaviors should be focused on to achieve precision bending forming. A three dimensional(3D) elastic-plastic finite element(FE) model of NC bending process was established under ABAQUS/Explicit platform, and its reliability was validated by the experiment. Then, numerical study on bending deformation behaviors under different frictions between tube and various dies was explored from multiple aspects such as wrinkling, wall thickness change and cross section deformation. The results show that the large friction of wiper die-tube reduces the wrinkling wave ratio η and cross section deformation degree ΔD and increases the wall thinning degree Δt. The large friction of mandrel-tube causes large η, Δt and ΔD, and the onset of wrinkling near clamp die. The large friction of pressure die-tube reduces Δt and ΔD, and the friction on this interface has little effect on η. The large friction of bending die-tube reduces η and ΔD, and the friction on this interface has little effect on Δt. The reasonable friction coefficients on wiper die-tube, mandrel-tube, pressure die-tube and bending die-tube of 21-6-9(0Cr21Ni6Mn9N) stainless steel tube in NC bending are 0.05-0.15, 0.05-0.15, 0.25-0.35 and 0.25-0.35, respectively. The results can provide a guideline for applying the friction conditions to establish the robust bending environment for stable and precise bending deformation of tube bending.

Friction behavior of Ti-30Fe composites strengthened by TiC particles

Ti-Fe-x TiC(x=0, 3, 6, 9, wt.%) composites were fabricated through low temperature ball milling of Ti, Fe and TiC powders, followed by spark plasma sintering. The results show that β-Ti, β-Ti-Fe, η-Ti4 Fe2 O0.4 and TiC particles can be found in the composites. The microstructure can be obviously refined with increasing the content of TiC particles. The coefficient of friction(COF) decreases and the hardness increases with increasing the content of TiC particles. The adhesive wear is the dominant wear mechanism of all the Ti-Fe-x TiC composites. The Ti-Fe-6 TiC composite shows the best wear resistance, owing to the small size and high content of TiC particle as well as relatively fine microstructure. The wear rate of the Ti-Fe-6 TiC composite is as low as 1.869× 10-5 mm3/(N·m) and the COF is only 0.64. Therefore, TiC particle reinforced Ti-Fe based composites may be utilized as potential wear resistant materials.

Friction Behaviors of the Hot Filament Chemical Vapor Deposition Diamond Film under Ambient Air and Water Lubricating Conditions

The friction behavior of the hot filament chemical vapor deposition（HFCVD） diamond film plays a critical role on its applications in mechanical fields and largely depends on the environment. Studies on the tribological properties of HFCVD diamond films coated on Co-cemented tungsten carbide （WC-Co） substrates are rarely reported in available literatures, especially in the water lubricating conditions. In this paper, conventional microcrystalline diamond（MCD） and fine-grained diamond（FGD） films are deposited on WC-Co substrates and their friction properties are evaluated on a reciprocating ball-on-plate tribometer, where they are brought to slide against ball-bearing steel and copper balls in dry and water lubricating conditions. Scanning electron microscopy（SEM）, atomic force microscopy（AFM）, surface profilometer and Raman spectroscopy are adopted to characterize as-deposited diamond films; SEM and energy dispersive X-ray（EDX） are used to investigate the worn region on the surfaces of both counterface balls and diamond films. The research results show that the friction coefficient of HFCVD diamond films always starts with a high initial value, and then gradually transits to a relative stable state. For a given counterface and a sliding condition, the FGD film presents lower stable friction coefficients by 0.02-0.03 than MCD film. The transferred materials adhered on sliding interface are supposed to have predominate effect on the friction behaviors of HFCVD diamond films. Furthermore, the effect of water lubricating on reducing friction coefficient is significant. For a given counterpart, the stable friction coefficients of MCD or FGD films reduce by about 0.07-0.08 while sliding in the water lubricating condition, relative to in dry sliding condition. This study is beneficial for widespread applications of HFCVD diamond coated mechanical components and adopting water lubricating system, replacing ofoil lubricating, in a variety of mechanical processing fields to implement the green production process.

Effect of tool plunge depth on the microstructure and fracture behavior of refill friction stir spot welded AZ91 magnesium alloy joints

We used refill friction stir spot welding(RFSSW)to join 2-mm-thick AZ91D-H24 magnesium alloy sheets,and we investigated in detail the effect of tool plunge depth on the microstructure and fracture behavior of the joints.A sound joint surface can be obtained using plunge depths of 2.0 and 2.5 mm.Plunge depth was found to significantly affect the height of the hook,with greater plunge depths corresponding to more severe upward bending of the hook,which compromised the tensile-shear properties of the joints.The hardness reached a minimum at the thermo-mechanically affected zone due to the precipitation phases of this zone as it dissolved into theα-matrix during the welding process.The fracture modes of RFSSW joints can be divided into three types:shear fracture,plug fracture,and shear–plug fracture.Of these,the joint with a shear–plug fracture exhibited the best tensile-shear load of 6400 N.

Friction Behavior on Contact Interface of Linear Ultrasonic Motor with Hard Contact Materials

How to improve the efficiency of the linear ultrasonic motor with hard contact materials(HLUSM)or the precision motion stage driven by HLUSM,becomes a hot issue.Analysis and testing of friction behavior on the contact interface of HLUSM is one of the key issues.Under the action of ultrasonic vibration and impact,the friction behavior on contact interface is very complex due to micro-amplitude and high frequency.Moreover,it is difficult to observe and test it.Focusing on the frictional behavior on the interface of HLUSM,a new method,through testing the vibration of the driving tips(scanning vibrometer PSV-400-3D)and the motion of the slider(displacement sensor LK-G30),respectively,is proposed.Then,take the HLUSM as an example,theoretical analyses and experiments are carried out.Theoretical analysis shows that the average speed of the slider should be 600 mm/s when there is no slippage between the stator and slider during the contact process.Experimental results show that the average speed of the slider is about 390mm/s.At the same time,the tangential vibration speed of the driving tip of HLUSM is larger than 600 mm/s.Therefore,there must be slippage between the stator and slider of HLUSM.Further experimental results show that the maximum efficiency is less than 10%.The slippage on the contact interface should be the main reason for the low efficiency of HLUSM.

Improving tribological behavior of friction stir processed A413/SiC_p surface composite using MoS_2 lubricant particles

The effect of MoS2 lubricant particles on the microstructure, microhardness and tribological behavior of A413/SiCp surface composite, fabricated via friction stir processing （FSP）, was studied. For this purpose, the FSP was carried out with tool rotational speed of 1600 r/min, tool travel speed of 25 mm/min and tool tilt angle of 3° through only a “single pass”. The optical and scanning electron microscopies, microhardness and reciprocating wear tests were used to characterize the samples. The results showed that the addition of MoS2 lubricant particles to A413/SiCp surface composite leads to the decrease of friction coefficient and mass loss. In fact, the generation of mechanically mixed layer （MML） containing MoS2 lubricant particles in A413/SiCp/MoS2p surface hybrid composite results in the reduction of metal-to-metal contact and subsequently leads to the improvement of tribological behavior.

Friction and wear behaviors of biodegradable Mg-6Gd-0.5Zn-0.4Zr alloy under simulated body fluid condition

The friction and wear behaviors of biodegradable Mg-6Gd-0.5Zn-0.4Zr(wt%,GZ60K)alloy were evaluated under simulated body fluid(SBF)condition using ball-on-disk configuration and compared with those under dry sliding condition.The results show that under dry sliding and SBF conditions,the friction coefficient declines with increasing applied load and keeps stable with prolonging sliding time.The friction coefficient of the alloy effectively decreases in SBF as compared to dry sliding due to lubrication caused by SBF.The real wear rates under SBF condition are lower than those under dry sliding condition for each parameter.Nevertheless,the nominal wear rates are higher in SBF which are attributed to the more mass loss caused by corrosion but not wear.Both the nominal wear rate in SBF and the dry sliding wear rate increase with increasing applied load,and they decline firstly and then keep stable with prolonging sliding time.It is concluded that the wear of the alloy is restricted by the SBF,but the corrosion of the alloy is aggravated by the wear.

Corrosion behavior of dissimilar copper/brass joints welded by friction stir lap welding in alkaline solution

This study was done to evaluate the nugget zone(NZ)corrosion behavior of dissimilar copper/brass joints welded by friction stir lap welding(FSLW)in a solution of 0.015 mol/L borax(pH 9.3).To this end,dissimilar copper/brass plates were welded with two dissimilar heat inputs(low and high)during the welding procedure.The high and low heat inputs were conducted with 710 r/min,16 mm/min and 450 r/min,25 mm/min,respectively.Using open circuit potential(OCP)measurements,electrochemical impedance spectroscopy(EIS)and Tafel polarization tests,the electrochemical behavior of the specimens in borate buffer solution was assessed.With the help of scanning electron microscope(SEM),the morphology of welded specimen surfaces was examined after immersion in the test solution.According to the results,the NZ grain size and resistance improvement reduced due to the nugget zone corrosion with a decreased heat input.The results obtained from Tafel polarization and EIS indicated the improved corrosion behavior of the welded specimen NZ with a decrease in the heat input during the welding process unlike the copper and brass metals.Furthermore,an increased heat input during the welding process shows a reduction in the conditions for forming the passive films with higher protection behavior.

Effect of zinc powder content on tribological behaviors of brake friction materials

Brake friction materials with different zinc powder contents(0,2,4,6,8 wt.%)were fabricated via powder metallurgy method.The results indicate that with the increasing zinc powder content,the density and thermal conductivity of the materials gradually increase,while the hardness decreases monotonously.With increasing zinc powder content,the curve of the nominal friction coefficient shows fluctuating trend but the lowest friction coefficient also shows an increase.However,the wear rate and braking noise of the friction material monotonously decrease with increasing zinc content.This effect may be attributed to the transformation of the tribological mechanism from adhesive wear and abrasive wear to adhesive wear.The brake friction material with 4 wt.%zinc powder exhibits both the best tribological and noise performance.

Friction and wear behavior of electrodeposited amorphous Fe-Co-W alloy deposits

The microstructures, friction and wear behavior under dry sliding condition of electrodeposited amorphous Fe-Co-W alloy deposits heat treated at different temperatures were studied. A comparative study of hard chrome deposit under the same testing condition was also made. The experimental results show that the hardness and wear resistance of amorphous Fe-Co-W alloy deposits are improved with the increasing of heat treatment temperature, and reach the maximum value at 800 ℃, then decrease above 800 ℃. Under 40 N load, the wear resistance properties of the alloy deposits heat treated at 800 ℃ are superior to those of hard chrome deposit. The main wear mechanisms of amorphous Fe-Co-W alloy deposits heat treated below 600 ℃ are peeling, plastic and flowing deformation; when the deposits are heat treated above 700 ℃, they are plastic and flowing deformation. While the main wear mechanisms of hard chrome are abrasive wear, fatigue and peeling.

Computational analysis of linear friction welding process and micromechanical modeling of deformation behavior for medium carbon steel

Finite element simulation of linear friction welding(LFW) medium carbon steel was carried out using the ABAQUS software. A two-dimensional(2D) coupled thermo-mechanical model was established. First, the temperature fields of medium carbon steel during LFW process were investigated. And then, the Mises stress and the 1st, 2nd and 3rd principal stresses fields' evolution of the steel during LFW process were studied. The deformation behavior of LFW carbon steel was analyzed by using micromechanics model based on ABAQUS with Python code. The Lode parameter was expressed using the Mohr stress circle and it was investigated in detail.

Friction and Wear Behavior of Ti-6Al-7Nb Biomaterial Alloy

Titanium has been increasingly applied to biomedical application because of its improved mechanical characteristics, corrosion resistance and biocompatibility. However their application remains limited, due to the low strength and poor wear resistance of unalloyed titanium. The purpose of this study is to evaluate the friction and wear behavior of high-strength titanium alloys: Ti-6Al-7Nb used in femoral stem (total hip prosthesis). The oscillating friction and wear tests have been carried out in ambient air with oscillating tribotester in accord with standards ISO 7148, ASTM G99-95a, ASTM G 133-95 under different conditions of normal applied load (3, 6 and 10 N) and sliding speed (1, 15 and 25 mm.s-1), and as a counter pair we used the ball of 100C 6, 10 mm of diameter. The surface morphology of the titanium alloys has been characterized by SEM, EDAX, micro hardness, roughness analysis measurements. The behavior observed for both samples suggests that the wear and friction mechanism during the test is the same for Ti alloys, and to increase resistance to wear and friction of biomedical titanium alloys used in total hip prosthesis (femoral stems) the surface coating and treatment are required.

Material flow behavior and microstructural evolution during refill friction stir spot welding of alclad 2A12-T4 aluminum alloy

In this study, we used the stop-action technique to experimentally investigate the material flow and microstructural evolution of alclad 2A12-T4 aluminum alloy during refill friction stir spot welding.There are two material flow components, i.e., the inward-or outward-directed spiral flow on the horizontal plane and the upward-or downward-directed flow on the vertical plane.In the plunge stage, the flow of plasticized metal into the cavity is similar to that of a stack, whereby the upper layer is pushed upward by the lower layer.In the refill stage, this is process reversed.As such, there is no obvious vertical plasticized metal flow between adjacent layers.Welding leads to the coarsening of S(Al2CuMg) in the thermo-mechanically affected zone and the diminishing of S in the stir zone.Continuous dynamic recrystallization results in the formation of fine equiaxed grains in the stir zone, but this process becomes difficult in the thermo-mechanically affected zone due to the lower deformation rate and the pinning action of S precipitates on the dislocations and sub-grain boundaries, which leads to a high fraction of low-angle grain boundaries in this zone.

Friction and Wear Behavior of Modified Layer Prepared on Ti-13Nb-13Zr Alloy by Magnetron Sputtering and Plasma Nitriding

Two kinds nitride modified layers were obtained on Ti-13Nb-13 Zr surface to improve the wear property via magnetron sputtering and plasma nitriding techniques, respectively. The structures of the modified layer and the worn surface after sliding test were characterized using X-ray diffraction（XRD） and scanning electron microscopy（SEM）. The friction and wear behavior of the modified layer against alumina ball was investigated in the absence of lubricant under different loads（1 N and 2 N）. The X-ray diffraction analysis reveals that nitride layer is mainly composed of TiN and Ti2N, while coating film consists of Ti N phase. Friction and wear test indicates that both modified layers can improve the wear resistance compared to untreated Ti-13Nb-13 Zr. Ti N thin film produces very hard surface, but may be easy to cause coating fracture and delamination under high normal load. However, nitride layer exhibits better wear performance. This is attributed to hard compound layer maintained its integrity with the hardened nitrogen diffusion zone during friction and wear process.