Nano-laminated graphene-carbide for green machining

Abstract Pure iron has recently been identified as the material basis of many high-tech industries due to its high toughness, plasticity as well as superior electromagnetism. However, the rather poor machinability has limited the wider applications of pure iron. Nano-laminated multilayer graphene-carbide tool (MLG/WC-Co) was produced employing two-step sintering. This study applied towards investigate the microstructure and mechanical properties of this MLG/WC-Co tool, highlighting its machining performance through dry turning pure iron. Results showed that compared with commercially available YG6 tool, MLG/WC-Co tool yielded reduced cutting forces, cutting temperature and friction coefficient at the tool-chip interface together with enhanced shear angle and tool life. The MLG/WC-Co tool developed cooperative adaptive mechanism for the coupled and interacted thermal-mechanical-chemical multi-fields were determined thoroughly. For one thing, the wear resistance was significantly enhanced as a function of the MLG introduced strengthening and toughening mechanisms. For another, cutting force induced tensile stress could be compensated by the residual compressive stress on the rake face resulting from the laminated structure. Furthermore, extensive MLG film formed at tool-chip interface at high-speed cutting conditions, endowing the cutting tool self-lubricating function coupled with exceptional adhesive-wear and oxidation resistance. Besides, the orientation conduction of cutting heat was proposed by associated consideration of tool structure as well as orientation distribution and anisotropic heat conductivity of MLG, so as to effectively slow down the heat accumulation and temperature rise. This research can ease the overwhelming pressure associated with sustainability by eradicating or circumventing the undesirable effects of traditional cutting fluids for economy, healthy coupled with environment through advancing dry machining techniques.