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Research Papers: Coatings and Solid Lubricants

Tribological Performance of MoS2-Filled Microtextured Cutting Tools During Dry Sliding Test

[+] Author and Article Information
Kishor Kumar Gajrani, Uday Shanker Dixit

Department of Mechanical Engineering,
Indian Institute of Technology Guwahati,
Guwahati 781 039, India

Mamilla Ravi Sankar

Department of Mechanical Engineering,
Indian Institute of Technology Guwahati,
Guwahati 781 039, India
e-mail: evmrs@iitg.ernet.in

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received March 7, 2017; final manuscript received June 26, 2017; published online September 29, 2017. Assoc. Editor: Robert Wood.

J. Tribol 140(2), 021301 (Sep 29, 2017) (11 pages) Paper No: TRIB-17-1075; doi: 10.1115/1.4037354 History: Received March 07, 2017; Revised June 26, 2017

Strict environmental laws enforced on manufacturing industries resulted in the development of alternative techniques to reduce or eliminate the use of lubricants during sliding contact as well as machining. Tribology plays a very important role for tool life in machining. To improve the life of cutting tool, cutting fluids are used. However, cutting fluids only penetrate into the region of sliding contact. In this study, the effect of surface texturing on plasma nitrided high-speed steel (HSS) pins during dry sliding test is investigated for understanding the performance of textured HSS tools in machining. Microtextures were fabricated using Vickers hardness tester on the surface of HSS pins. Tribological tests of molybdenum disulphide (MoS2) filled as well as unfilled microtextured HSS with area density of textures varying from 2% to 14% were performed with the aid of pin-on-disk tribometer against an abrasive sheet. Friction and wear performance were assessed in terms of the pin surface temperature, coefficient of friction (COF), wear, weight loss of the pin and wear rate. Worn-out test surfaces were observed under scanning electron microscope to understand the wear mechanism. The best results were obtained with MoS2-filled microtextures having 10% texture area density. Tool–chip interface temperature, cutting force, feed force, and centerline average (CLA) surface roughness were also assessed during machining test with 10% area density of textured cutting tools.

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Figures

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Fig. 1

Unfilled and MoS2-filled textured surfaces of HSS pins: (a) macroscopic view of unfilled texture, (b) surface micrograph of unfilled texture, (c) three-dimensional (3D) profile of unfilled texture, (d) macroscopic view of MoS2-filled textured pin, (e) MoS2-filled texture surface micrograph, (f) 3D profile of MoS2-filled texture, (g) two-dimensional (2D) profile of an unfilled texture, and (h) 2D profile of MoS2-filled texture

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Fig. 2

Experimental setup of pin-on-disk tribometer along with thermal imaging camera

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Fig. 3

Variation of coefficient of friction of the HSS pin with sliding time at constant speed of 30 m/min for the loads of (a) 19.6 N (without MoS2), (b) 19.6 N (with MoS2), (c) 49 N (without MoS2), and (d) 49 N (with MoS2)

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Fig. 4

Variation of HSS pin surface temperature with sliding time at a constant speed of 30 m/min for the normal load of (a) 19.6 N (without MoS2), (b) 19.6 N (with MoS2), (c) 49 N (without MoS2), and (d) 49 N (with MoS2)

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Fig. 5

Thermal images of pin surface temperature of UT, A10, A10-M pins during sliding test with sliding speed of 30 m/min for the normal load of (a) 19.6 N and (b) 49 N

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Fig. 6

Variation of wear of the HSS pin with sliding time at constant speed of 30 m/min for the load of (a) 19.6 N (without MoS2), (b) 19.6 N (with MoS2), (c) 49 N (without MoS2), and (d) 49 N (with MoS2)

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Fig. 7

Variation of weight loss of the HSS pin with respect to texture area density

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Fig. 8

Variation of wear rate of the HSS pin with respect to texture area density

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Fig. 9

(a) Untextured pin, (b) MoS2-filled textured pin, and (c) formation of lubricating film between sliding interfaces

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Fig. 10

Surface micrograph of (a) tested unfilled textured pin micro-indent, (b) tested MoS2-filled textured pin micro-indent, (c) EDS map of iron for tested unfilled textured pin micro-indent, (d) EDS map of iron for tested MoS2-filled textured pin micro-indent, (e) EDS map of molybdenum for tested unfilled textured pin micro-indent, (f) EDS map of molybdenum for tested MoS2-filled textured pin micro-indent, (g) EDS map of sulfur for tested unfilled textured pin micro-indent, and (h) EDS map of sulfur for tested MoS2-filled textured pin micro-indent at 500× magnification

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Fig. 11

(a) Surface morphology of untextured pin, (b) elemental composition of untextured pin at corresponding area A, (c) surface morphology of unfilled textured pin micro-indent, (d) elemental composition of unfilled textured pin micro-indent at corresponding area B, (e) surface morphology of MoS2-filled textured pin micro-indent, and (f) elemental composition of MoS2-filled textured pin micro-indent at corresponding area C after sliding tests

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Fig. 12

Variation of (a) tool–chip interface temperature and (b) machining forces with untextured, unfilled textured and MoS2-filled textured cutting tools

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Fig. 13

Variation of workpiece average surface roughness with untextured, unfilled textured and MoS2-filled textured cutting tools

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