Solid lubricants are environmental friendly (green) because they reduce tool wear, the usage of chemical-based cutting fluids, friction and heat during the manufacturing process. In addition, solid lubricants are reusable and easy to handle. Therefore, the solid lubricants that are required in manufacturing processes are efficient, inexpensive, and easily acquired. The present work investigates the usage of different commercial boron compounds (boric acid, boron oxide, boron pentahydrate, and Etidot-67) as lubricants and their performances regarding surface quality, cutting forces and tool wear while machining AISI 1020 steel using HSS end mills. The performance of boron compounds was studied in comparison with that of dry machining. During the metal-cutting process, constant values of the depth of cut, cutting speed and feed rate were used. In the process of milling, the cutting forces were measured with the dynamometer simultaneously. The results indicate that there is a considerable improvement in the machining performance with commercial boron compounds. As a result of using boric acid as a solid lubricant, tool wear resistance improved, the surface roughness values decreased approximately 20 to 32%, and the values of the cutting forces decreased by approximately 15 to 50% compared with dry end milling.
Plasma transferred arc (PTA) welding methods were used to produce titanium carbide (TiC) composite coating layers on the surface of 38MnVS6 steel and subsequently deep cryogenic treatment (DCT) was applied to the PTA coating layers. The effects of the TiC powder, different energy inputs (100 and 120A), and DCT on the microstructure and tribological performance were investigated. The microstructure of the composite coatings consisted of cubic TiC, unmelted TiC, and iron matrix. The alloyed and cryogenic treated surfaces exhibited decreases in the coefficient of friction (COF) and wear rate. The average COF of the steel substrate was determined to be 0.373, but for the TiC composite coating layers it varied between 0.236 and 0.33. PTA coating and DCT processes improved the wear resistance 4.5 times compared to the substrate.
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