Sprayed Coating Machining with Oil Infiltration for CBN Tool Life
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Solution Overview
Problem
Conventional methods for cutting sprayed coatings using cutting tools with cubic boron nitride edges face severe wear due to thermal shock caused by water-soluble coolants, leading to reduced tool life, and existing methods for machining sintered materials require reduced pressure for oil infiltration, which is not applicable to all scenarios.
Innovation Solution
A method involving a cutting tool with a cutting edge of cubic boron nitride coated with a layer of TiCN, TiAlN, or AlCrN, where the voids in the sprayed coating are infiltrated with a lubricating oil under atmospheric pressure, followed by dry-cutting to reduce thermal shock and enhance tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water-soluble coolant is supplied to the cutting edge when cutting sprayed coating, then cooling effect is improved, but thermal shock causes severe wear and reduces tool life
Solution Approach 1:
The patent introduces lubricating oil as an intermediary substance that penetrates into the voids of the sprayed coating before cutting. This oil acts as a mediator between the cutting tool and the workpiece, providing lubrication and reducing thermal shock during the cutting process, thereby extending tool life while maintaining effective cutting
2Reliability
If completely dry machining is used when cutting sprayed coating with cubic boron nitride, then thermal shock is reduced, but lubrication is insufficient leading to increased wear
Solution Approach 1:
The patent applies lubricating oil to the sprayed coating surface before the cutting operation begins. This preliminary action allows the oil to penetrate and fill the voids in the sprayed coating structure, so that when cutting commences, the lubrication is already in place, reducing wear while avoiding the thermal shock problems associated with water-soluble coolants
3Object-affected harmful factors
If oil is supplied to infiltrate voids in sprayed coating, then lubrication is improved, but reduced pressure is required which complicates the process
Solution Approach 1:
The patent exploits the porous structure of the sprayed coating, which contains inherent voids and pores. By applying lubricating oil to this porous surface, the oil naturally penetrates into the voids through capillary action and adsorption, eliminating the need for reduced pressure equipment or complex infiltration systems while still achieving effective lubrication
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method improves the tool life of the cutting tool by reducing thermal shock and maintaining sufficient lubrication without increasing wear, even when cutting edges are made of cubic boron nitride, and allows for effective cutting without the need for reduced pressure.
Implementation Method 1
the voids in the sprayed coating are infiltrated with a lubricating oil under atmospheric pressure
Implementation Method 2
the lubricating oil forms an adsorbed film on the cutting edge
Implementation Method 3
the water-soluble coolant, which has a high coolability, efficiently cools the cutting edge that is cutting the sprayed coating including the voids, thereby causing a strong thermal shock on the cutting edge
Implementation Method 4
supplying the lubricating oil to the cutting edge in a boundary lubrication state
Implementation Method 5
the lubricating oil forms an adsorbed film on the cutting edge
Data Source
Figure 1~2
Figure 3~4
Figure 5A~6
AI summary
A method for manufacturing a member according to one embodiment of the present disclosure is a method for manufacturing a member having a substrate and a sprayed coating formed on a surface of the substrate. The method for manufacturing the member according to one embodiment of the present disclosure includes: supplying an oil into a recessed portion of the sprayed coating, a kinematic viscosity of the oil at 40°C being more than or equal to 3 mm2/s and less than or equal to 43 mm2/s; and dry-cutting, using a cutting tool, a surface of the sprayed coating with the recessed portion supplied with the oil. At least a portion of the cutting tool is constituted of a sintered material of cubic boron nitride, and a cutting edge of the cutting tool is formed at the sintered material of cubic boron nitride. A supplied amount of the oil is more than or equal to 0.1 weight % and less than or equal to 2.7 weight % with respect to an apparent weight of the sprayed coating.