SURFNANOCUT - Knowledge based cutting for surface engineering of aeronautic and automotive materials: understanding the fundamentals of cutting process through micro-nano structure analysis

In the majority of hi-tech applications, where aeronautics and automotive belongs to, the functional quality of metal parts is to be achieved by final machining, which in general case results in deterioration of such important properties of the surface as strength, fatigue and corrosion resistance. Previous collaboration with MPEG at MU in a MICROMAQUINTE project (funded by the Cobierno Vasco) has revealed the influence of process parameters of cutting on the microstructure of the processed material and that the resulting nanocrystalline surface may have mechanical properties much superior to the bulk of the same composition. In that research the investigation of the microstructure of the material has played the key role in understanding of thermomechanical conditions at the tool/workpiece interface and has allowed to pinpoint the driving forces for triggering microstructure formation processes. In the current proposal we are going to study these microstructural processes in a broader range of the materials, and to utilize this knowledge for controlling the surface properties after machining.

The idea of the current application is understanding the patterns of the surface layer microstructure generation during cutting and utilization of this knowledge for targeted engineering of the final piece surface properties just by changing the parameters of cutting. We plan to explore the potential of the idea on key materials of aeronautics and automotive sectors: AISI 1045 steel, Inconel 718 and Aluminum 7475. In the current proposal we will explore the variety of microstructures, which can be obtained in realistic cutting conditions. On the base of thus acquired data we will develop models connecting process parameters (speed, feed, tool geometry) via process characteristics (strain, strain rate, temperature) to resulting microstructure and use these models in predictive simulations. As a key method for model development we will use micro-cutting, which allows to reveal the intimate details of cutting process. In parallel we will characterize the micro-mechanical properties of surface microstructure obtained in cutting experiments in order to understand to which extend we can modify the surface. Substantial effort will be devoted to exploring the potential of atomistic simulations for prediction of the mechanisms of plastic deformation in cutting conditions and establishing a link between such simulations and continuous media models.

This research is oriented to the goals of the Societal Challenge for a Transporte sostenible, inteligente, conectado e integrado through exploring the novel concepts for machining of materials used for construction of high-tech vehicles with the final aim to increase the quality and durability of metal components within the existing machining workflow without the necessity for additional processing steps. This may generate significant contributions to the competitiveness of the Spanish and European transport industries and achieve resource-efficient transport systems that are climate-and-environmentally-friendly, safe and seamless for the benefit of all citizens, the economy and society. Moreover, the objectives pursued by the project can also provide strong contributions for priorities settled within other Societal Challenges identified in Plan Estatal de Investigación Científica y Técnica y de Innovación 2017-2020, such as Climate action, environment, resource efficiency and raw materials.

This project is funded by RTI2018-095463-B-C22/MCIN/ AEI /10.13039/501100011033/ y por FEDER Una manera de hacer Europa