The Additive Action of Some Organic Chlorides and Sulfides in the Four-Ball Lubricant Test

When tested by the four-ball extreme-pressure procedure, oil solutions of t-octyl chloride at the 2 percent chlorine level rated approximately equal to oil solutions of di-t-octyl disulfide at the 2 percent sulfur level, and both of these additive blends rated better than n-octyl chloride in oil at the 2 percent chlorine level or di-n-octyl disulfide in oil at the 2 percent sulfur level. n-Octyl chloride and di-n-octyl disulfide in oil at corresponding concentrations of active element were approximately equivalent in additive action. t-Octyl chloride was almost as good at the 1 percent as at the 2 percent chlorine level. Mixtures of di-t-octyl disulfide and t-octyl chloride in oil at the level 1 percent S-1 percent Cl rated approximately twice as well as di-t-octyl disulfide (2 percent S) or t-octyl chloride (2 percent Cl). Some finer points of the action of these additives were investigated by studying time-connected behavior at 50-kg and 100-kg loads. The action of the additives cannot be explained on the basis of their chemical structures only; interactions with the rubbing process in the four-ball machine also must be considered.     

Erosion Debris Particle Observations and the Micromachining Mechanism of Erosion

Erosion debris particles produced by particle impact erosion of pure Ni and a stainless steel have been examined in the scanning electron microscope for the purpose of determining whether micro-machining is an operative mechanism of erosion by alumina particles. Macroscopic machining chips generally exhibit well-defined lamellae on the side of the chip away from the tool face, and such lamellae are also observed in micromachining chips produced by abrasion or scratch testing. The aspect ratio of such chips is generally large. In the present work, the aspect ratios and shapes of erosion debris particles formed at angles of incidence below the peak erosion angle (α_c) were generally consistent with the dimensions of the impact craters formed on the eroded surface and with the hypothesis that they were formed by micromachining. However, most of the debris particles did not exhibit characteristic lamellae. This may be explained by the fact that the surface from which they are formed is very rough even on a scale similar to the size of the debris particles. This is not true in abrasion: Micromachining chips formed from such a surface would be expected to have surfaces which would obscure the existence of lamellae. However, some chips would be expected to come from the few relatively smooth areas of the surface, and these should show lamellae. Examples of such chips were, indeed, found, and micrographs of these chips are nearly indistinguishable from micrographs of micromachining chips formed by abrasion or scratch tests. It is concluded that micromachining is an operative mechanism of erosion which is of greatest importance at low angles of incidence. Debris particles formed at higher angles of incidence are generally more platelike.     

Micro cutting of tungsten carbides with sem direct observation method

This paper describes the micro cutting of wear resistant tungsten carbides using PCD (Poly-Crystalline Diamond) cutting tools in performance with SEM (Scanning Electron Microscope) direct observation method. Turning experiments were also carried out on this alloy (V50) using a PCD cutting tool. One of the purposes of this study is to describe clearly the cutting mechanism of tungsten carbides and the behavior of WC particles in the deformation zone in orthogonal micro cutting. Other purposes are to achieve a systematic understanding of machining characteristics and the effects of machining parameters on cutting force, machined surface and tool wear rates by the outer turning of this alloy carried out using the PCD cutting tool during these various cutting conditions. A summary of the results are as follows : (1) From the SEM direct observation in cutting the tungsten carbide, WC particles are broken and come into contact with the tool edge directly. This causes tool wear in which portions scrape the tool in a strong manner. (2) There are two chip formation types. One is where the shear angle is comparatively small and the crack of the shear plane becomes wide. The other is a type where the shear angle is above 45 degrees and the crack of the shear plane does not widen. These differences are caused by the stress condition which gives rise to the friction at the shear plane. (3) The thrust cutting forces tend to increase more rapidly than the principal forces, as the depth of cut and the cutting speed are increased preferably in the orthogonal micro cutting. (4) The tool wear on the flank face was larger than that on the rake face in the orthogonal micro cutting. (5) Three components of cutting force in the conventional turning experiments were different in balance from ordinary cutting such as the cutting of steel or cast iron. Those expressed a large value of thrust force, principal force, and feed force. (6) From the viewpoint of high efficient cutting found within this research, a proper cutting speed was 15 m/min and a proper feed rate was 0.1 mm/rev. In this case, it was found that the tool life of a PCD tool was limited to a distance of approximately 230 m. (7) When the depth of cut was 0.1 mm, there was no influence of the feed rate on the feed force. The feed force tended to decrease, as the cutting distance was long, because the tool was worn and the tool edge retreated. (8) The main tool wear of a PCD tool in this research was due to the flank wear within the maximum value of V_max being about 260 μ.