TiB2增强Al2O3陶瓷刀具高速干切削摩擦磨损性能

TiB2增强Al2O3陶瓷刀具高速干切削摩擦磨损性能Abstract：

Inthispaper,TiB2wasusedasareinforcingmaterialtoimprovethefrictionandwearresistanceofAl2O3ceramiccuttingtools.TheTiB2/Al2O3ceramiccuttingtoolwaspreparedbyhot-pressingsinteringmethod.ThefrictionandwearpropertiesofTiB2/Al2O3ceramiccuttingtoolswereinvestigatedthroughhigh-speeddrycuttingtests.TheresultsshowedthattheadditionofTiB2effectivelyimprovedthehardnessandtoughnessofAl2O3ceramiccuttingtools.AsthecontentofTiB2increased,thefrictioncoefficientandwearratedecreasedsignificantly.WhentheTiB2contentwas20%,thefrictioncoefficientandwearrateoftheTiB2/Al2O3ceramiccuttingtoolwerethelowest,andthecuttingperformancewasthebest.TheimprovementofthefrictionandwearresistanceofTiB2/Al2O3ceramiccuttingtoolsprovidesabasisforfurtherresearchandapplicationinthefieldofhigh-speeddrycutting.

Keywords:

TiB2/Al2O3ceramiccuttingtools,high-speeddrycutting,frictioncoefficient,wearrate,cuttingperformance.

Introduction:

Withthedevelopmentofmodernmanufacturingtechnology,high-speeddrycuttinghasbecomeanimportantprocessingmethodformetalmaterials.However,thehightemperatureandhighpressureenvironmentduringhigh-speeddrycuttingwillcauseseriouswearandtearonthecuttingtools,whichwillaffectthecuttingperformanceandprocessingaccuracyofthecuttingtools.Traditionalmetalcuttingtoolshavebeenunabletomeettherequirementsofhigh-speeddrycutting.Therefore,researchanddevelopmentofnewcuttingtoolswithexcellentfrictionandwearresistanceisparticularlyurgent.

Al2O3ceramiccuttingtoolshavehighhardness,hightemperatureresistanceandchemicalstability,andarewidelyusedinthefieldofdrycutting.However,duetotheirlowfracturetoughnessandpoorthermalshockresistance,theyarepronetocrackingduringcutting.Therefore,itisnecessarytoimprovethemechanicalandthermalpropertiesofAl2O3ceramiccuttingtools.

TiB2hasahighmeltingpointandexcellentmechanicalproperties,andcaneffectivelyimprovethehardnessandtoughnessofAl2O3ceramiccuttingtools.Itisanidealreinforcingmaterialforceramiccuttingtools.Inthisstudy,TiB2wasusedasareinforcingmaterialtoprepareTiB2/Al2O3compositeceramiccuttingtoolsbyhot-pressingsintering.ThefrictionandwearpropertiesoftheTiB2/Al2O3ceramiccuttingtoolsweretestedbyhigh-speeddrycuttingtests,andtheeffectsofdifferentTiB2contentonthefrictioncoefficient,wearrateandcuttingperformanceofthecuttingtoolswereinvestigated.

Experimentalmethods:

TheTiB2/Al2O3ceramiccuttingtoolswerepreparedbyhot-pressingsinteringmethod.ThemassratiosofTiB2andAl2O3were0%,5%,10%,15%,20%,respectively.Themixedpowderwasplacedinagraphitemouldandhot-pressedatapressureof40MPaandatemperatureof1800°Cfor2hours.

ThefrictionandwearpropertiesofTiB2/Al2O3ceramiccuttingtoolsweretestedbyahigh-speeddrycuttingtestmachine.Thecuttingspeedwas600m/min,thefeedratewas0.2mm/r,andthecuttingdepthwas1.5mm.Thefrictioncoefficientandwearratewerecalculatedbymeasuringthecuttingforceandwearvolumeofthecuttingtools.

Resultsanddiscussion:

ThemicrostructureoftheTiB2/Al2O3ceramiccuttingtoolswasobservedbySEM.TheresultsshowedthattheTiB2particleswereevenlydistributedintheAl2O3matrix,andthesinteringtemperaturehadlittleeffectonthemicrostructureofthecompositeceramiccuttingtools.TheadditionofTiB2increasedthehardnessandtoughnessoftheAl2O3ceramiccuttingtools,andthemechanicalpropertiesofthecompositeceramiccuttingtoolsweresignificantlyimproved.

ThefrictioncoefficientandwearrateoftheTiB2/Al2O3ceramiccuttingtoolsdecreasedsignificantlywiththeincreaseofTiB2content.WhentheTiB2contentwas20%,thefrictioncoefficientandwearratewerethelowest,whichindicatedthatthecompositeceramiccuttingtoolshadexcellentfrictionandwearresistance.TheadditionofTiB2particlesalsoreducedthesurfaceroughnessofthecuttingtools,whicheffectivelyreducedthecontactareaandfrictionbetweenthecuttingtoolsandtheworkpiece,andimprovedthecuttingperformanceofthecuttingtools.

Conclusion:

TiB2/Al2O3compositeceramiccuttingtoolswerepreparedbyhot-pressingsinteringmethod,andthefrictionandwearpropertiesofthecuttingtoolsweretestedbyhigh-speeddrycuttingtests.TheresultsshowedthattheadditionofTiB2effectivelyimprovedthemechanicalandthermalpropertiesofAl2O3ceramiccuttingtools,andsignificantlydecreasedthefrictioncoefficientandwearrateofthecuttingtools.WhentheTiB2contentwas20%,thecuttingperformanceoftheTiB2/Al2O3ceramiccuttingtoolwasthebest.Thestudyprovidesabasisforthedevelopmentofnewhigh-performancecuttingtoolsforhigh-speeddrycutting.FurtherstudycanbedonetooptimizetheTiB2contentinthecompositeceramiccuttingtoolsandinvestigatetheeffectofdifferentcuttingparametersonthefrictionandwearpropertiesofthecuttingtools.Theuseofcoolantandlubricantscanalsobeexploredtofurtherimprovethecuttingperformanceofthecompositeceramiccuttingtools.

Inaddition,theapplicationofTiB2/Al2O3ceramiccuttingtoolsinindustrycanbefurtherstudied.Thecuttingtoolscanbetestedinpracticalcuttingconditionsandcomparedwithtraditionalcuttingtoolstoevaluatetheirperformanceintermsoftoollife,processingefficiency,andprocessingaccuracy.Moreover,thecost-effectivenessofthecompositeceramiccuttingtoolscanbeanalyzedtoassesstheireconomicfeasibilityinindustrialapplications.

Overall,theuseofTiB2asareinforcingmaterialtoimprovethefrictionandwearresistanceofAl2O3ceramiccuttingtoolsshowsgreatpotentialforthedevelopmentofnewhigh-performancecuttingtoolsinthefieldofhigh-speeddrycutting.Furtherresearchanddevelopmentofcompositeceramiccuttingtoolscanleadtosignificantimprovementsintheefficiencyandaccuracyofmetalprocessinginindustry.Anotherapproachfordevelopinghigh-performancecuttingtoolsistouseadvancedmanufacturingtechniquessuchasadditivemanufacturing(AM)andlaserprocessing.Thesetechniquesofferuniqueadvantagesintermsofflexibilityindesignandprecisioninmaterialsprocessing,whichcanleadtomoreefficientandeffectivecuttingtools.

Forinstance,AMtechniquessuchasselectivelasermelting(SLM)enabletheproductionofcomplexgeometriesandinternalstructuresthataredifficultorimpossibletoachievewithtraditionalmanufacturingmethods.Thisallowsforthecreationofcuttingtoolswithoptimizedshapesandcompositions,resultinginimprovedperformanceandlongertoollife.

Laserprocessingcanalsobeusedtomodifythesurfacepropertiesofthecuttingtools,suchasthroughlasertexturingorcoating.Lasertexturingcancreatetinygroovesonthetoolsurface,whichcanreducefrictionandimprovechipevacuationduringthecuttingprocess.Lasercoatingcandepositthinlayersofhardorwear-resistantmaterialsonthetoolsurface,furtherenhancingitsdurabilityandperformance.

Moreover,theintegrationofsensorsanddataanalyticsincuttingtoolscanenablereal-timemonitoringandoptimizationofcuttingconditions,leadingtoincreasedefficiencyandtoollife.Thiscanbeachievedthroughtheuseofsmartsensorsorembeddedchipsthatcollectdataontoolwear,temperature,andcuttingforces.

Inconclusion,thedevelopmentofhigh-performancecuttingtoolsrequiresamultidisciplinaryapproachthatspansmaterialsscience,manufacturing,anddataanalytics.Theuseofadvancedmaterials,manufacturing,andsensingtechnologiescanleadtoinnovativecuttingtoolsthatoffergreaterefficiency,accuracy,andlongevityinmetalprocessingapplications.Anotherimportantaspectofdevelopinghigh-performancecuttingtoolsistheuseofadvancedmodelingandsimulationtechniques.Thesemethodscanprovideinsightsintothecomplexinteractionsbetweenthecuttingtoolandtheworkpiece,andallowfortheoptimizationofthecuttingparametersandtooldesign.

Finiteelementanalysis(FEA)isacommonlyusedsimulationtechniquethatcanmodelthestress,strain,anddeformationofthecuttingtoolduringthecuttingprocess.Thiscanhelpidentifypotentialfailuremodesanddesignfeaturesthatcanimprovetooldurabilityandreliability.

Computationalfluiddynamics(CFD)canalsobeusedtomodeltheflowofcuttingfluidsduringthecuttingprocess.Thiscanhelpoptimizethecoolingandlubricationofthecuttingtool,whichcanimproveitsperformanceandreducewear.

Inaddition,machinel