Al_2O_3基微纳复合陶瓷刀具材料及其切削性能研究
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摘要
高速切削加工是未来切削加工技术的发展方向,而刀具材料是发展高速切削加工技术的关键,开发适于高速干式切削加工的陶瓷刀具契合了当今绿色环保的理念。本文以研制高性能微纳复合陶瓷刀具材料为目标,对微纳复合陶瓷刀具材料进行了系统设计,优化了微纳复合陶瓷刀具材料的制备工艺,成功制备出Al2O3/TiC/ZrO2微纳复合陶瓷刀具材料,并对其力学性能、微观组织结构、动态本构模型及切入瞬时仿真、切削性能、失效形式及机理进行了研究。
基于超高强度钢的切削加工特点,提出了微纳复合陶瓷刀具材料的设计原则,并设计出以微米Al203为基体,微米TiC、纳米TiC和纳米Zr02为添加相的微纳复合陶瓷刀具材料。通过对其进行化学相容性计算分析,可知在烧结及切削加工过程中不会发生化学反应。基于颗粒残余应力模型,计算出微米级TiC和Zr02的最大体积分数,分别为82.8vol%和21.3vol%。根据各组分的物理相容性的计算分析,确定纳米添加相的成分,并基于等径球体紧密排列结构,依据素坯颗粒级配原则,建立了纳米添加相的粒径和体积分数的理论模型,并考虑纳米粒子的团聚效应,确定了纳米TiC的粒径为80nm,含量为4vol%;纳米Zr02的粒径为40nm,含量为1.5-2.0vol%。基于液态金属对TiC的润湿性,确定了添加金属Ni、Mo及含量。
研究了纳米粉末的分散工艺。研究结果表明,悬浮液为PH值9-10的碱性溶液,分散剂PEG添加量为纳米TiC粉末质量的1.5wt%时,纳米TiC悬浮液的相对沉降体积小；悬浮液为PH值9-10的碱性溶液,分散剂PEG添加量约为纳米Zr02粉末质量的2wt%时,纳米Zr02悬浮液的相对沉降体积小。
研究了微纳复合陶瓷刀具材料的烧结工艺。对烧结温度和保温时间进行了优化。结果表明,微纳复合陶瓷刀具材料适宜的烧结工艺为：烧结温度1700℃,保温时间10min,烧结压力30MPa。依据烧结体的性能,对组分配比进行优选,成功制备出综合性能优良的ATZ4微纳复合陶瓷刀具材料,其抗弯强度、维氏硬度、断裂韧度和相对密度分别为970MPa、20.3GPa、5.9MPa·m1/2和99.3%。
研究分析了ATZ4微纳复合陶瓷刀具材料的微观结构和断裂模式。结果表明,其微观结构为晶内／晶间型,且晶粒尺寸大小分布均匀；其断裂模式是以穿晶断裂为主的混合断裂模式。
研究了ATZ4微纳复合陶瓷刀具材料的强韧化机理。结果表明,其主要的强韧化机理为晶粒细化、晶界强化、位错强韧化、相变增韧、裂纹偏转和颗粒桥接增韧。
建立了ATZ4微纳复合陶瓷刀具材料动态本构模型,并仿真了瞬时切入过程。基于滑移型裂纹模型,应用细观损伤力学理论,建立了ATZ4微纳复合陶瓷刀具材料单轴压缩下损伤型动态本构方程。通过分离式霍普金森压杆实验获取ATZ4微纳复合陶瓷材料的动态应力-应变曲线,并与理论曲线进行对比分析,验证了理论公式的合理性。建立了ATZ4微纳复合陶瓷刀具切削仿真的有限元模型,获得了切入瞬时刀具前刀面上最大拉应力,并根据第一强度理论,预测了刀具切入工件时可能的破损失效,为切削参数的选择提供了依据。
建立了ATZ4微纳复合陶瓷刀具切削加工调质300M钢的刀具寿命模型,分析了ATZ4微纳复合陶瓷刀具在合理切削参数下的失效形式及机理。对比分析研究了不同刀具切削调质300M钢时的切削性能、磨损破损形式及其机理。结果表明,在低速车削时,刀具均以磨损为主,其机理为粘结磨损和磨粒磨损；在高速车削时,刀具的失效形式为磨损和破损,其磨损机理为粘结磨损和磨粒磨损,而破损机理为机械应力和热应力的耦合作用。在高速切削条件下,其耦合应力较高,易达到刀具材料的强度极限而造成其破裂。在各切削速度下,ATZ4较其它刀具均表现出更强的耐磨损和抗破损的能力。
High-speed machining is the development direction of future machining technology, and the cutting tool material is the key to the development of high speed machining technology, so the development of ceramic cutting tools is suitable for high speed dry cutting to meet the requirement of green environmental protection today. In this dissertation, the development of high-performance micro-nano-composite ceramic cutting tool material is chosen as the research objective. Through systematically designing the micro-nano-composite ceramic tool material and optimizing the fabrication processing parameters on the micro-nano-composite ceramic tool material, Al2O3/TiC/ZrO2micro-nano-composite ceramic tool material is successfully prepared, then its mechanical properties, microstructure, dynamic constitutive relation, dynamic simulation of cutting process, the cutting performance and failure modes and mechanisms are studied.
Based on machining characteristics of ultra-high strength steel, the design principles of micro-nano-composite ceramic tool material are proposed, and with the micron Al2O3as matrix, micron TiC, nano TiC and nano ZrO2as additives, the composition of micro-nano-composite ceramic tool material is determined. The analysis and calculation on the chemical compatibility show that there is no chemical reaction in the process of sintering and machining. Based on the particle residual stress model, the largest volume content of micron TiC and ZrO2are determined as82.8%and21.3%, respectively. According to the physical compatibility analysis and calculation of each constituent, the nano additive phase composition is determined. Based on close-packed arrangement of equal diameter balls and the principle of grain composition of green compact, the theoretical models for nano additive particle size and volume content are established. By considering the aggregation effect of nanoparticles, the particle size and content of the nano additive are determined. The volume fraction of nano TiC with the diameter of80nm is4vol%, and the volume fraction of nano ZrO2with the diameter of40nm is1.5～2.0vol%. Based on wettability of TiC, the Ni and Mo additives and its content are determined.
Dispersion process of nano powder was investigated. Results show when the suspension is an alkaline solution of PH9～10and dispersant PEG amount for nano TiC powder is1.5wt%of nanometer TiC powder quality, relative sedimentation of TiC nanoparticles suspension is lowest, and when suspension is an alkaline solution of PH9-10and dispersant PEG amount is about2wt%of nanometer ZrO2powder quality, relative sedimentation of nanometer ZrO2suspension is smallest.
The sintering process of micro-nano-composite ceramic tool materials is studied. The sintering temperature and holding time for hot pressing sintering were optimized. The sintering temperature1700℃, holding time10min and sintering pressure30MPa are suitable for micro-nano-composite ceramic tool material. The constituents ratio are optimized on the basis of the performance of the sintered body, then ATZ4micro-nano-composite ceramic tool material with the highest synthetical properties is produced, and its flexural strength, fracture toughness and Vickers' hardness and relative density are970MPa,5.9MPa·m1/2,20.3GPa and99.3%, respectively.
The microstructure and fracture pattern of ATZ4micro-nano-composite ceramic tool material are studied. Results show that the microstructure is mainly of intragranular/intergranular structure, and uniform grain size distribution. Its fracture modes are mixed by transgranular fracture and intergranular fracture.
Strenthening and toughening mechanisms for ATZ4micro-nano-composite ceramic tool material are studied. Results show that the main strenthening and toughening mechanisms of ATZ4are grain refining, grain boundary strengthening, dislocation strengthening and toughening, phase transformation toughening, crack deflection and grain bridging.
The dynamic constitutive model of ATZ4micro-nano-composite ceramic tool material and the machining process simulation are studied. Based on the sliding crack model and applying the theory of meso-damage mechanics, the damage type dynamic constitutive equation of ATZ4under uniaxial compression is established. The dynamic stress-strain curve of ATZ4is obtained by SHPB (Split Hopkinson Pressure Bar) test equipment, and compared with theoretical stress-strain curve, so that the rationality of the theoretical formula was verified. The finite element model of cutting simulation for ATZ4is established and the tool rake face maximum tensile stress is obtained. According to the maximum tensile stress theory, damage failure of cutting tool is predicted when it cut into the workpiece, providing a guidance for cutting parameter selection.
The empirical formula of cutting tool life in turning300M steel is established, and the cutting parameters are optimized. The failure modes and mechanism of cutting tool under the reasonable cutting parameters are analyzed. Cutting performance, failure mode and mechanisms of different cutting tools in machining300M steel are studied. Results show that in low speed turning, the failure mode of the cutting tool is tool wear, and its mechanism is adhesive wear and abrasive wear. In high-speed turning, the failure mode of cutting tool is tool wear and breakage. The wear mechanism is adhesive wear and abrasive wear. The cutting tool is loaded by the coupling stress of the mechanical stress and thermal stress in machining, and when the couple stress is equal to the ultimate strenghth of the tool material, the cutting tool may fracture. Under different cutting speeds, the fracture and wear resistance properties of ATZ4micro-nano-composite ceramic tool are higher than other cutting tools.
This work was financially supported by the National Basic Research Program of China(2009CB724402) and the Scientific Research Foundation for the Excellent Middle-Aged and Youth Scientists of Shandong Province of China(BS2011ZZ010).
基于超高强度钢的切削加工特点,提出了微纳复合陶瓷刀具材料的设计原则,并设计出以微米Al203为基体,微米TiC、纳米TiC和纳米Zr02为添加相的微纳复合陶瓷刀具材料。通过对其进行化学相容性计算分析,可知在烧结及切削加工过程中不会发生化学反应。基于颗粒残余应力模型,计算出微米级TiC和Zr02的最大体积分数,分别为82.8vol%和21.3vol%。根据各组分的物理相容性的计算分析,确定纳米添加相的成分,并基于等径球体紧密排列结构,依据素坯颗粒级配原则,建立了纳米添加相的粒径和体积分数的理论模型,并考虑纳米粒子的团聚效应,确定了纳米TiC的粒径为80nm,含量为4vol%;纳米Zr02的粒径为40nm,含量为1.5-2.0vol%。基于液态金属对TiC的润湿性,确定了添加金属Ni、Mo及含量。
研究了纳米粉末的分散工艺。研究结果表明,悬浮液为PH值9-10的碱性溶液,分散剂PEG添加量为纳米TiC粉末质量的1.5wt%时,纳米TiC悬浮液的相对沉降体积小；悬浮液为PH值9-10的碱性溶液,分散剂PEG添加量约为纳米Zr02粉末质量的2wt%时,纳米Zr02悬浮液的相对沉降体积小。
研究了微纳复合陶瓷刀具材料的烧结工艺。对烧结温度和保温时间进行了优化。结果表明,微纳复合陶瓷刀具材料适宜的烧结工艺为：烧结温度1700℃,保温时间10min,烧结压力30MPa。依据烧结体的性能,对组分配比进行优选,成功制备出综合性能优良的ATZ4微纳复合陶瓷刀具材料,其抗弯强度、维氏硬度、断裂韧度和相对密度分别为970MPa、20.3GPa、5.9MPa·m1/2和99.3%。
研究分析了ATZ4微纳复合陶瓷刀具材料的微观结构和断裂模式。结果表明,其微观结构为晶内／晶间型,且晶粒尺寸大小分布均匀；其断裂模式是以穿晶断裂为主的混合断裂模式。
研究了ATZ4微纳复合陶瓷刀具材料的强韧化机理。结果表明,其主要的强韧化机理为晶粒细化、晶界强化、位错强韧化、相变增韧、裂纹偏转和颗粒桥接增韧。
建立了ATZ4微纳复合陶瓷刀具材料动态本构模型,并仿真了瞬时切入过程。基于滑移型裂纹模型,应用细观损伤力学理论,建立了ATZ4微纳复合陶瓷刀具材料单轴压缩下损伤型动态本构方程。通过分离式霍普金森压杆实验获取ATZ4微纳复合陶瓷材料的动态应力-应变曲线,并与理论曲线进行对比分析,验证了理论公式的合理性。建立了ATZ4微纳复合陶瓷刀具切削仿真的有限元模型,获得了切入瞬时刀具前刀面上最大拉应力,并根据第一强度理论,预测了刀具切入工件时可能的破损失效,为切削参数的选择提供了依据。
建立了ATZ4微纳复合陶瓷刀具切削加工调质300M钢的刀具寿命模型,分析了ATZ4微纳复合陶瓷刀具在合理切削参数下的失效形式及机理。对比分析研究了不同刀具切削调质300M钢时的切削性能、磨损破损形式及其机理。结果表明,在低速车削时,刀具均以磨损为主,其机理为粘结磨损和磨粒磨损；在高速车削时,刀具的失效形式为磨损和破损,其磨损机理为粘结磨损和磨粒磨损,而破损机理为机械应力和热应力的耦合作用。在高速切削条件下,其耦合应力较高,易达到刀具材料的强度极限而造成其破裂。在各切削速度下,ATZ4较其它刀具均表现出更强的耐磨损和抗破损的能力。
High-speed machining is the development direction of future machining technology, and the cutting tool material is the key to the development of high speed machining technology, so the development of ceramic cutting tools is suitable for high speed dry cutting to meet the requirement of green environmental protection today. In this dissertation, the development of high-performance micro-nano-composite ceramic cutting tool material is chosen as the research objective. Through systematically designing the micro-nano-composite ceramic tool material and optimizing the fabrication processing parameters on the micro-nano-composite ceramic tool material, Al2O3/TiC/ZrO2micro-nano-composite ceramic tool material is successfully prepared, then its mechanical properties, microstructure, dynamic constitutive relation, dynamic simulation of cutting process, the cutting performance and failure modes and mechanisms are studied.
Based on machining characteristics of ultra-high strength steel, the design principles of micro-nano-composite ceramic tool material are proposed, and with the micron Al2O3as matrix, micron TiC, nano TiC and nano ZrO2as additives, the composition of micro-nano-composite ceramic tool material is determined. The analysis and calculation on the chemical compatibility show that there is no chemical reaction in the process of sintering and machining. Based on the particle residual stress model, the largest volume content of micron TiC and ZrO2are determined as82.8%and21.3%, respectively. According to the physical compatibility analysis and calculation of each constituent, the nano additive phase composition is determined. Based on close-packed arrangement of equal diameter balls and the principle of grain composition of green compact, the theoretical models for nano additive particle size and volume content are established. By considering the aggregation effect of nanoparticles, the particle size and content of the nano additive are determined. The volume fraction of nano TiC with the diameter of80nm is4vol%, and the volume fraction of nano ZrO2with the diameter of40nm is1.5～2.0vol%. Based on wettability of TiC, the Ni and Mo additives and its content are determined.
Dispersion process of nano powder was investigated. Results show when the suspension is an alkaline solution of PH9～10and dispersant PEG amount for nano TiC powder is1.5wt%of nanometer TiC powder quality, relative sedimentation of TiC nanoparticles suspension is lowest, and when suspension is an alkaline solution of PH9-10and dispersant PEG amount is about2wt%of nanometer ZrO2powder quality, relative sedimentation of nanometer ZrO2suspension is smallest.
The sintering process of micro-nano-composite ceramic tool materials is studied. The sintering temperature and holding time for hot pressing sintering were optimized. The sintering temperature1700℃, holding time10min and sintering pressure30MPa are suitable for micro-nano-composite ceramic tool material. The constituents ratio are optimized on the basis of the performance of the sintered body, then ATZ4micro-nano-composite ceramic tool material with the highest synthetical properties is produced, and its flexural strength, fracture toughness and Vickers' hardness and relative density are970MPa,5.9MPa·m1/2,20.3GPa and99.3%, respectively.
The microstructure and fracture pattern of ATZ4micro-nano-composite ceramic tool material are studied. Results show that the microstructure is mainly of intragranular/intergranular structure, and uniform grain size distribution. Its fracture modes are mixed by transgranular fracture and intergranular fracture.
Strenthening and toughening mechanisms for ATZ4micro-nano-composite ceramic tool material are studied. Results show that the main strenthening and toughening mechanisms of ATZ4are grain refining, grain boundary strengthening, dislocation strengthening and toughening, phase transformation toughening, crack deflection and grain bridging.
The dynamic constitutive model of ATZ4micro-nano-composite ceramic tool material and the machining process simulation are studied. Based on the sliding crack model and applying the theory of meso-damage mechanics, the damage type dynamic constitutive equation of ATZ4under uniaxial compression is established. The dynamic stress-strain curve of ATZ4is obtained by SHPB (Split Hopkinson Pressure Bar) test equipment, and compared with theoretical stress-strain curve, so that the rationality of the theoretical formula was verified. The finite element model of cutting simulation for ATZ4is established and the tool rake face maximum tensile stress is obtained. According to the maximum tensile stress theory, damage failure of cutting tool is predicted when it cut into the workpiece, providing a guidance for cutting parameter selection.
The empirical formula of cutting tool life in turning300M steel is established, and the cutting parameters are optimized. The failure modes and mechanism of cutting tool under the reasonable cutting parameters are analyzed. Cutting performance, failure mode and mechanisms of different cutting tools in machining300M steel are studied. Results show that in low speed turning, the failure mode of the cutting tool is tool wear, and its mechanism is adhesive wear and abrasive wear. In high-speed turning, the failure mode of cutting tool is tool wear and breakage. The wear mechanism is adhesive wear and abrasive wear. The cutting tool is loaded by the coupling stress of the mechanical stress and thermal stress in machining, and when the couple stress is equal to the ultimate strenghth of the tool material, the cutting tool may fracture. Under different cutting speeds, the fracture and wear resistance properties of ATZ4micro-nano-composite ceramic tool are higher than other cutting tools.
This work was financially supported by the National Basic Research Program of China(2009CB724402) and the Scientific Research Foundation for the Excellent Middle-Aged and Youth Scientists of Shandong Province of China(BS2011ZZ010).
引文
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