原位反应自润滑陶瓷刀具的设计开发及其减摩机理研究
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摘要
本文提出了原位反应自润滑陶瓷刀具的概念,即：利用刀具切削高温作用下的摩擦化学反应,在刀具材料表面原位生成具有润滑作用的反应膜,从而实现刀具的自润滑。研制成功以Al2O3为基体、ZrB2为增强相、ZrO2为弥散相的新型自润滑陶瓷刀具材料,并对其制备工艺、性能、微观结构、摩擦磨损特性及自润滑机理、切削性能及减摩机理进行了深入的研究。
在对刀具切削加工的摩擦特点分析的基础上,提出了原位反应自润滑陶瓷刀具材料的设计原则,确定了自润滑刀具的材料体系；对原位反应自润滑陶瓷刀具材料配方进行了优选,并设计出Al2O3／ZrB2／ZrO2原位反应陶瓷刀具材料；对自润滑陶瓷刀具材料进行了化学物理相容性设计,结果表明在热压烧结过程中不会发生化学反应,同时确定了添加相的极限体积含量；对自润滑陶瓷刀具材料进行了摩擦学设计,热力学结果证明了切削中原位反应能够发生,同时分析了润滑膜的减摩机理。
利用热压烧结工艺制备出Al2O3／ZrB2／ZrO2自润滑刀具材料(AZ系列自润滑材料),对材料的配比及烧结压力、保温时间等工艺参数进行了优选,并确定了最佳值。经研究发现,采用二次球磨工艺,当ZrB2／ZrO2含量为20%,在烧结温度为1700℃,烧结压力为30MPa,保温时问为20min时,可以制备出综合力学性能最好的自润滑刀具材料AZ20,其维氏硬度为23.1GPa,抗弯强度为760.9MPa,断裂韧性为6.19MPa·m1／2。在此基础上,进行了材料相组成扫描和显微结构观察,研究了球磨细化工艺对材料性能与微观结构的影响,并分析了原位反应自润滑陶瓷刀具材料内在的增韧补强机制。
提出了自润滑陶瓷刀具材料高温氧化模型,根据复合材料的相关物性参数,模拟出Al2O3／ZrB2／ZrO2自润滑刀具材料在氧化温度θ<1000℃的氧化简图,并对AZ系列材料在900℃时氧化增重进行了预测。对AZ系列自润滑陶瓷刀具材料进行了高温氧化试验,研究了不同条件下自润滑陶瓷刀具材料的高温氧化特性,其氧化增重大体符合抛物线规律。理论预测曲线与实际氧化曲线的大体趋势相似,试验的氧化增重数值比理论预测的值要高,主要因为理论模型过于理想化,实际影响氧化增重的因素较多所致。随着氧化时间的增加,AZ系列自润滑材料氧化速率逐渐降低,氧化进程逐渐缓慢。主要因为氧化生成的ZrO2覆盖在材料的表面,一定程度上阻碍了复合材料继续氧化。AZ系列自润滑材料在不同温度下氧化20h后,力学性能均有不同程度下降,其中,当氧化温度为700℃时下降明显。氧化试验和X射线衍射结果表明复合材料在500～700℃时已开始氧化。
对原位反应自润滑陶瓷刀具材料的摩擦特性及减摩机理进行了研究。建立了摩擦磨损过程中接触区平均压力与最高温度的解析计算式。研究了ZrB2／ZrO2含量、摩擦速度和环境温度对AZ系列自润滑刀具材料的摩擦磨损特性的影响,对润滑膜的转移与破坏机理进行了深入分析,同时探讨了不同摩擦条件下原位反应自润滑的作用。结果表明：AZ系列自润滑刀具材料的摩擦系数随ZrB2／ZrO2含量的增加而降低,当ZrB2／ZrO2含量为20%时,其磨损率最小,由于该陶瓷材料的综合力学性能在AZ系列材料中最好,并且在摩擦中其表面形成了一层润滑膜,改善了摩擦性能,有助于磨损率的降低。AZ20自润滑陶瓷材料摩擦系数和磨损率总体上随着摩擦速度和环境温度的升高呈现下降的趋势。主要因为原位反应后有ZrO2和B2O3的生成,其在高温下具有一定的润滑性,不易产生粘结磨损。
研究了原位反应自润滑陶瓷刀具的切削性能及减摩机理。AZ20陶瓷刀具在空气中切削45号正火钢和淬火钢时,当切削深度ap=0.2mm,进给量f=0.1mm／r,切削速度v超过160m／min时,刀具表面可以发生原位反应自润滑,形成了ZrO2和B2O3自润滑膜,具有一定的减摩特性,不易产生粘结磨损,并使得切削时刀具的磨损较均匀,不易发生崩刃的情况。由于原位反应自润滑的作用,AZ20陶瓷刀具在空气中切削45号正火钢和淬火钢时,后刀面磨损、切削力、摩擦系数和已加工工件的表面粗糙度总体上要比AZ20在氮气环境和SG4在空气环境中切削时低。在切削深度ap=0.2mm,进给量f=0.1mm／r,切削速度v=160m／min的切削条件下,切削45号正火钢时,AZ20自润滑刀具的寿命较SG4陶瓷刀具提高了17.6%；切削45号淬火钢时,寿命较SG4陶瓷刀具提高了20%。提出了一种考虑材料与摩擦特性的切削温度场仿真方法,试验均值与仿真结果值相差不大且变化趋势较为一致。
The concept of self-lubricating ceramic tool base on in-situ reaction is proposed in this paper, namely that by the friction chemical reaction under high-temperature, generate the lubricating film on the cutting tool surface to achieve the self-lubricating tools. A new self-lubricating cutting tool material has been developed successfully with adding reinforcement phase-ZrB2 and dispersed phase-ZrO2 to Al2O3 matrix, as well as its ratio design, fabrication process, properties, microstructures, tribological behaviors and cutting performance more over, the antifriction mechanism are studied in detail.
On the analyzing of friction characteristics in cutting process, the design principles of self-lubricating ceramic tool material is proposed and the material system is also determined. Optimize the composition of the materials, meanwhile, the Al2O3/ZrB2/ZrO2 self-lubricating ceramic tool material is designed. Analysis of physical and chemical compatibility of self-lubricating material determine that there is no chemical reaction in the hot pressing sintering process, and make sure the maximum volume content of additions. Tribological design of self-lubricating ceramic tool material is proposed, and thermodynamic results show that in-situ reaction could occur in machining proces, meanwhile, the antifriction mechanism is analyzed.
Self-lubricating tool materials of Al2O3/ZrB2/ZrO2 ceramic (AZ series) are fabricated by technology of the hot-pressing sintering. Test results of material properties give a preferred value for ratio of materials, sintering pressure and holding time. By detailed X-ray diffraction and microstructure analysis, toughening and strengthening mechanisms are derived. Based on the above conclusions, the effect of ball milling refinement on properties and microstructure of Al2O3/ZrB2/ZrO2 ceramic materials are investigated. AZ20 ceramic composite shows higher synthetic mechanical properties in AZ series self-lubricating materials with double milling refinement technology, when the sintering temperature is 1700℃, pressure is 30MPa, holding time is 20min and the volume of ZrB2/ZrO2 is 20%. The optimized properties are:Vicker's hardness 23.1GPa, bending strength 760.9MPa and fracture toughness 6.19 MPa-m1/2.
The oxidation model of self-lubricating ceramic tool materials is proposed. According to the relevant physical properties of the composite, simplified oxidation surface of Al2LO3/ZrB2/ZrO2 at oxidation temperatureθ<1000℃is simulated, and the weight gains of AZ series self-lubricating ceramic materials are predicted. High temperature oxidation experiments of AZ series self-lubricating ceramic materials are conducted under different conditions, and oxidation behavior of the composite is studied, and the weight gains accord with parabolic law characteristics, and the general trend of the oxidation curves experimental weight gain is obviously greater than the forecast model, the reason is that the theoretical models is idealistic and many more factors can affect the oxidation process. Oxidation rate of the self-lubricating materials decreases with increasing the oxidation time, and the oxidation process change to slow gradually. This is because the generated ZrO2 on the surface can prevent continued oxidation of the composite materialsin a sence. The mechanical properties of AZ series ceramic materials decrease in varying degrees when oxidate 20 hours at different temperatures, and has obvious decline at 700℃. Oxidation test and XRD analysis indicated that the composites began to oxidate at 500～700℃.
The tribological properties and antifriction mechanisms of in-situ reaction self-lubricating ceramic tool materials are studied. Analytic equations of the average pressure and maximum temperature in contact area are established. The effects of ZrB2/ZrO2 content, friction velocity and environmental temperature on the tribological behaviors of AZ self-lubricating ceramic tool materials are studied in detail, and the relevant researchs about the transfer and failure mechanisms of self-lubricating film are analyzed. Moreover, antifriction functions of self-lubrication in different conditions are discussed. The results show that:the friction coefficient of AZ self-lubricating ceramic tool material decrease with the increasing of ZrB2/ZrO2 content, and the wear rate can reach to the minimum data when the ZrB2/ZrO2 content is 20%. The reason is that the mechanical properties of AZ self-lubricating material is the best at this time, and the lubricating film generated on the friction surface can improve the tribological behavior and reduce the wear rate. The friction coefficient and wear rate of AZ20 composite decrease with the increasing of friction speed or environmental temperature. This is because the in-situ reaction can generate the ZrO2 and B2O3 self-lubricating film, which can improve the tribological behavior and prevent the adhesive wear at high temperature.
The cutting performance and anti-friction mechanism of self-lubricating ceramic tool base on in-situ reaction are studied. Dry cutting of normalized and hardened 45# steel in air with AZ20 self-lubricating ceramic tool, when the cutting depth ap= 0.2mm, feed rate f= 0.lmm/r, cutting speed v exceeds 160m/min, a self-lubricating film of ZrO2 and B2O3 is formed on the friction surface of AZ20 in cutting process, which has an anti-friction behavior and can prevent the adhesive wear. With the self-lubricating base on in-situ reaction, it was found that the tool wear is homogeneous and no chipping situation. According to the effect of self-lubricating, the tool flank wear, cutting force, friction coefficient and surface roughness of machined workpiece when dry cutting of normalized and hardened 45# steel in air with AZ20 tool are reduced compared SG4 in the air and AZ20 in nitrogen environment. Under the same cutting conditions that the cutting depth ap= 0.2mm, feed rate f= 0.1mm/r, cutting speed v= 160m/min, the tool life of AZ20 ceramic tool is prolonged more than 17.6% compared the SG4 tool when machining normalized 45# steel, and 20% when machining hardened 45# steel. A simulation way of cutting temperature field considering property of materials and friction is is proposed, and the results of simulation agree with experiment.
在对刀具切削加工的摩擦特点分析的基础上,提出了原位反应自润滑陶瓷刀具材料的设计原则,确定了自润滑刀具的材料体系；对原位反应自润滑陶瓷刀具材料配方进行了优选,并设计出Al2O3／ZrB2／ZrO2原位反应陶瓷刀具材料；对自润滑陶瓷刀具材料进行了化学物理相容性设计,结果表明在热压烧结过程中不会发生化学反应,同时确定了添加相的极限体积含量；对自润滑陶瓷刀具材料进行了摩擦学设计,热力学结果证明了切削中原位反应能够发生,同时分析了润滑膜的减摩机理。
利用热压烧结工艺制备出Al2O3／ZrB2／ZrO2自润滑刀具材料(AZ系列自润滑材料),对材料的配比及烧结压力、保温时间等工艺参数进行了优选,并确定了最佳值。经研究发现,采用二次球磨工艺,当ZrB2／ZrO2含量为20%,在烧结温度为1700℃,烧结压力为30MPa,保温时问为20min时,可以制备出综合力学性能最好的自润滑刀具材料AZ20,其维氏硬度为23.1GPa,抗弯强度为760.9MPa,断裂韧性为6.19MPa·m1／2。在此基础上,进行了材料相组成扫描和显微结构观察,研究了球磨细化工艺对材料性能与微观结构的影响,并分析了原位反应自润滑陶瓷刀具材料内在的增韧补强机制。
提出了自润滑陶瓷刀具材料高温氧化模型,根据复合材料的相关物性参数,模拟出Al2O3／ZrB2／ZrO2自润滑刀具材料在氧化温度θ<1000℃的氧化简图,并对AZ系列材料在900℃时氧化增重进行了预测。对AZ系列自润滑陶瓷刀具材料进行了高温氧化试验,研究了不同条件下自润滑陶瓷刀具材料的高温氧化特性,其氧化增重大体符合抛物线规律。理论预测曲线与实际氧化曲线的大体趋势相似,试验的氧化增重数值比理论预测的值要高,主要因为理论模型过于理想化,实际影响氧化增重的因素较多所致。随着氧化时间的增加,AZ系列自润滑材料氧化速率逐渐降低,氧化进程逐渐缓慢。主要因为氧化生成的ZrO2覆盖在材料的表面,一定程度上阻碍了复合材料继续氧化。AZ系列自润滑材料在不同温度下氧化20h后,力学性能均有不同程度下降,其中,当氧化温度为700℃时下降明显。氧化试验和X射线衍射结果表明复合材料在500～700℃时已开始氧化。
对原位反应自润滑陶瓷刀具材料的摩擦特性及减摩机理进行了研究。建立了摩擦磨损过程中接触区平均压力与最高温度的解析计算式。研究了ZrB2／ZrO2含量、摩擦速度和环境温度对AZ系列自润滑刀具材料的摩擦磨损特性的影响,对润滑膜的转移与破坏机理进行了深入分析,同时探讨了不同摩擦条件下原位反应自润滑的作用。结果表明：AZ系列自润滑刀具材料的摩擦系数随ZrB2／ZrO2含量的增加而降低,当ZrB2／ZrO2含量为20%时,其磨损率最小,由于该陶瓷材料的综合力学性能在AZ系列材料中最好,并且在摩擦中其表面形成了一层润滑膜,改善了摩擦性能,有助于磨损率的降低。AZ20自润滑陶瓷材料摩擦系数和磨损率总体上随着摩擦速度和环境温度的升高呈现下降的趋势。主要因为原位反应后有ZrO2和B2O3的生成,其在高温下具有一定的润滑性,不易产生粘结磨损。
研究了原位反应自润滑陶瓷刀具的切削性能及减摩机理。AZ20陶瓷刀具在空气中切削45号正火钢和淬火钢时,当切削深度ap=0.2mm,进给量f=0.1mm／r,切削速度v超过160m／min时,刀具表面可以发生原位反应自润滑,形成了ZrO2和B2O3自润滑膜,具有一定的减摩特性,不易产生粘结磨损,并使得切削时刀具的磨损较均匀,不易发生崩刃的情况。由于原位反应自润滑的作用,AZ20陶瓷刀具在空气中切削45号正火钢和淬火钢时,后刀面磨损、切削力、摩擦系数和已加工工件的表面粗糙度总体上要比AZ20在氮气环境和SG4在空气环境中切削时低。在切削深度ap=0.2mm,进给量f=0.1mm／r,切削速度v=160m／min的切削条件下,切削45号正火钢时,AZ20自润滑刀具的寿命较SG4陶瓷刀具提高了17.6%；切削45号淬火钢时,寿命较SG4陶瓷刀具提高了20%。提出了一种考虑材料与摩擦特性的切削温度场仿真方法,试验均值与仿真结果值相差不大且变化趋势较为一致。
The concept of self-lubricating ceramic tool base on in-situ reaction is proposed in this paper, namely that by the friction chemical reaction under high-temperature, generate the lubricating film on the cutting tool surface to achieve the self-lubricating tools. A new self-lubricating cutting tool material has been developed successfully with adding reinforcement phase-ZrB2 and dispersed phase-ZrO2 to Al2O3 matrix, as well as its ratio design, fabrication process, properties, microstructures, tribological behaviors and cutting performance more over, the antifriction mechanism are studied in detail.
On the analyzing of friction characteristics in cutting process, the design principles of self-lubricating ceramic tool material is proposed and the material system is also determined. Optimize the composition of the materials, meanwhile, the Al2O3/ZrB2/ZrO2 self-lubricating ceramic tool material is designed. Analysis of physical and chemical compatibility of self-lubricating material determine that there is no chemical reaction in the hot pressing sintering process, and make sure the maximum volume content of additions. Tribological design of self-lubricating ceramic tool material is proposed, and thermodynamic results show that in-situ reaction could occur in machining proces, meanwhile, the antifriction mechanism is analyzed.
Self-lubricating tool materials of Al2O3/ZrB2/ZrO2 ceramic (AZ series) are fabricated by technology of the hot-pressing sintering. Test results of material properties give a preferred value for ratio of materials, sintering pressure and holding time. By detailed X-ray diffraction and microstructure analysis, toughening and strengthening mechanisms are derived. Based on the above conclusions, the effect of ball milling refinement on properties and microstructure of Al2O3/ZrB2/ZrO2 ceramic materials are investigated. AZ20 ceramic composite shows higher synthetic mechanical properties in AZ series self-lubricating materials with double milling refinement technology, when the sintering temperature is 1700℃, pressure is 30MPa, holding time is 20min and the volume of ZrB2/ZrO2 is 20%. The optimized properties are:Vicker's hardness 23.1GPa, bending strength 760.9MPa and fracture toughness 6.19 MPa-m1/2.
The oxidation model of self-lubricating ceramic tool materials is proposed. According to the relevant physical properties of the composite, simplified oxidation surface of Al2LO3/ZrB2/ZrO2 at oxidation temperatureθ<1000℃is simulated, and the weight gains of AZ series self-lubricating ceramic materials are predicted. High temperature oxidation experiments of AZ series self-lubricating ceramic materials are conducted under different conditions, and oxidation behavior of the composite is studied, and the weight gains accord with parabolic law characteristics, and the general trend of the oxidation curves experimental weight gain is obviously greater than the forecast model, the reason is that the theoretical models is idealistic and many more factors can affect the oxidation process. Oxidation rate of the self-lubricating materials decreases with increasing the oxidation time, and the oxidation process change to slow gradually. This is because the generated ZrO2 on the surface can prevent continued oxidation of the composite materialsin a sence. The mechanical properties of AZ series ceramic materials decrease in varying degrees when oxidate 20 hours at different temperatures, and has obvious decline at 700℃. Oxidation test and XRD analysis indicated that the composites began to oxidate at 500～700℃.
The tribological properties and antifriction mechanisms of in-situ reaction self-lubricating ceramic tool materials are studied. Analytic equations of the average pressure and maximum temperature in contact area are established. The effects of ZrB2/ZrO2 content, friction velocity and environmental temperature on the tribological behaviors of AZ self-lubricating ceramic tool materials are studied in detail, and the relevant researchs about the transfer and failure mechanisms of self-lubricating film are analyzed. Moreover, antifriction functions of self-lubrication in different conditions are discussed. The results show that:the friction coefficient of AZ self-lubricating ceramic tool material decrease with the increasing of ZrB2/ZrO2 content, and the wear rate can reach to the minimum data when the ZrB2/ZrO2 content is 20%. The reason is that the mechanical properties of AZ self-lubricating material is the best at this time, and the lubricating film generated on the friction surface can improve the tribological behavior and reduce the wear rate. The friction coefficient and wear rate of AZ20 composite decrease with the increasing of friction speed or environmental temperature. This is because the in-situ reaction can generate the ZrO2 and B2O3 self-lubricating film, which can improve the tribological behavior and prevent the adhesive wear at high temperature.
The cutting performance and anti-friction mechanism of self-lubricating ceramic tool base on in-situ reaction are studied. Dry cutting of normalized and hardened 45# steel in air with AZ20 self-lubricating ceramic tool, when the cutting depth ap= 0.2mm, feed rate f= 0.lmm/r, cutting speed v exceeds 160m/min, a self-lubricating film of ZrO2 and B2O3 is formed on the friction surface of AZ20 in cutting process, which has an anti-friction behavior and can prevent the adhesive wear. With the self-lubricating base on in-situ reaction, it was found that the tool wear is homogeneous and no chipping situation. According to the effect of self-lubricating, the tool flank wear, cutting force, friction coefficient and surface roughness of machined workpiece when dry cutting of normalized and hardened 45# steel in air with AZ20 tool are reduced compared SG4 in the air and AZ20 in nitrogen environment. Under the same cutting conditions that the cutting depth ap= 0.2mm, feed rate f= 0.1mm/r, cutting speed v= 160m/min, the tool life of AZ20 ceramic tool is prolonged more than 17.6% compared the SG4 tool when machining normalized 45# steel, and 20% when machining hardened 45# steel. A simulation way of cutting temperature field considering property of materials and friction is is proposed, and the results of simulation agree with experiment.
引文
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