Green manufacturing: Creating high strenght metal matrix structures-II (HybridSurd-II)

Purpose and goal

Hard turning is used within some sectors due to the advantages that the process offers, such as machining hard materials with complex shape using standard cutting tool and using minimum quantity lubrication (energy efficiency and environmentally friendly). However, there are still a few challenges that needs to be addressed and have limited the process to only be used in semi-finishing or on non-critical surfaces. This project targeted some of the challenges, and the outcome was positive, where the process drawbacks was converted into strengths, with a focus on surface integrity.

Expected results and effects

The focus of the project was to evaluate the possbility to create M-WL from start during hard turning and also characterise the structure/surface integrity of the created surfaces. The project showed on the possibility that by optimizing the process setting using certain cutting tools, MWL can be produced directly. Also there was a focus to increase the productivity compared to previously used cutting data. We were also able show on the potential to increase the productivity, by a factor of 2, in this project.

Planned approach and implementation

The project has been carried out between RISE and Chalmers, where all tests have been manufactured with help of MCR at Chalmers. The characterization of the generated surfaces (LOM, SEM, XRD and surface analyses) were shared between RISE and Chalmers, where various expert/post-doc and senior researchers have been supported the project. Also in the early phase an industrial reference group where created, to both anchoring the project and also get support in terms of material, cutting tools etc. The results have been only communicated to the industrial group, but will be published soon.