Control over multi-scale self-organization-based processes under the extreme tribological conditions of cutting through the application of complex adaptive surface-engineered systems

Abstract

This paper features a comprehensive analysis of various multiscale selforganization processes that occur during cutting. A thorough study of entropy production during friction has uncovered several channels of its reduction that can be achieved by various selforganization processes. These processes are (1) self-organization during physical vapor deposition PVD coating deposition on the cutting tool substrates; (2) tribofilm formation caused by interactions with the environment during operation, which consist of the following compounds: thermal barriers; Magnéli phase tribo-oxides with metallic properties at elevated temperatures, tribo-oxides that transform into a liquid phase at operating temperatures, and mixed action tribo-oxides that serve as thermal barriers/lubricants, and (3) multiscale selforganization processes that occur on the surface of the tool during cutting, which include chip formation, the generation of adhesive layers, and the buildup edge formation. In-depth knowledge of these processes can be used to significantly increase the wear resistance of the coated cutting tools. This can be achieved by the application of the latest generation of complex adaptive surface-engineered systems represented by several state-of-the-art adaptive nano-multilayer PVD coatings, as well as high entropy alloy coatings (HEAC).