Improving the efficiency of machine parts and cutting tools using combined processing methods

Юрій Вячеславович Широкий, Юрій Олександрович Сисоєв, Ольга Діонісівна Семененко, Олена Василівна Торосян

Abstract


Combined strengthening mechanisms significantly improve the operational durability of cutting tools (CT) and machine-building parts. The application of simultaneous ion implantation along with plasma deposition of coatings based on molybdenum and tungsten ensures an increase in the wear resistance of steel parts by 2–10 times compared to materials treated with coating alone. Similarly, for hard and high-speed alloys, the combination of ion-plasma nitriding with nitride coatings increases wear resistance by 1.5–3 times. The effectiveness of such coatings and modified layers is determined by the parameters of integrated technologies, such as ion energy, fluence, substrate temperature, and plasma atmosphere composition. Research demonstrates that combined strengthening promotes the formation of nanostructured layers, leading to microhardness up to 46 GPa, an increase in cutting tool life by up to 65 times, part wear resistance by up to 60 times, corrosion resistance by up to 3.7 times, and fatigue strength by up to 1.7 times. Particularly indicative is the increase in fatigue strength, which confirms the formation of nanostructures during combined processing. These nanostructures, such as nanocomposites with grain sizes of 10-50 nm, hinder crack propagation and enhance surface plasticity. For a deeper understanding, ion implantation involves accelerating ions (e.g., N+ or C+) to energies of 50-200 keV, modifying the surface to a depth of up to 1 μm. Plasma deposition, such as PVD or CVD, deposits layers with a thickness of 1-10 μm, creating a barrier against wear. The combination of these methods synergistically improves adhesion, reducing delamination by 1.5-2 times. In practice, for steel parts like 42CrMo4, such processing is applied in machine building for gears and shafts, extending service life in aggressive environments. Regarding hard alloys like WC-Co, plasma nitriding at 400-600°C saturates the surface with nitrogen, forming nitrides, while nitride coatings (TiN, CrN) add a protective layer. This is particularly effective for mills and drills, where wear is reduced due to a decrease in the friction coefficient to 0.1-0.3 Development prospects include integration with additive technologies for gradient structures, which will enable even higher resistance indicators. Overall, combined strengthening is key to modern materials science, ensuring resource savings and increased equipment reliability in industries from machine building to aerospace.

Keywords


combined machining, surface layer strengthening, increased wear resistance, part service life, cutting tool, increased machining productivity

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