基于元胞自动机模型的陶瓷刀具材料及其切削性能研究
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摘要
陶瓷刀具具有较高的硬度、耐磨性、耐热性,较为适用于难加工材料的高效加工,但现有的陶瓷刀具材料研制方法多以试验为主,可设计性差,特别是烧结过程微观组织结构的设计和优化没有较为系统的指导,使得新型陶瓷刀具材料的开发没有合适的理论指导,也较难获得力学性能理想的陶瓷刀具材料。
本文利用元胞自动机模型,考虑了二相粒子、烧结助剂和烧结致密化过程,将烧结过程的主要参数保温时间、烧结温度、烧结压力耦合进元胞自动机模型,进行了Al2O3/TiN复相陶瓷刀具材料烧结过程的模拟,最后通过烧结实验验证了理论分析,结果表明模拟分析的结果与实际烧结实验结果符合很好。以此理论研究为指导结合实验研制了ATN50材料,并在其基础上研制成功了ATCN50b复合陶瓷刀具材料。利用ATCN50b陶瓷刀具进行了高效切削1Crl3马氏体不锈钢的性能研究,结果表明,在高速下刀具寿命和工件加工的表面粗糙度都优于现有的几种复合陶瓷刀具和常用硬质合金刀具。
对元胞自动机算法进行了研究,确定了最大取向值对模拟结果的影响,考虑到实际烧结过程中主要参数的影响,将烧结时的保温时间、烧结温度、烧结压力耦合进了元胞自动机模型。基于晶界能与晶界曲率的变化的理论,建立了耦合实际烧结过程主要参数的两相陶瓷刀具材料的元胞自动机模型,实现了Al2O3/TiN两相陶瓷刀具材料烧结过程微观组织结构演变的模拟。研究了烧结过程中的晶粒生长情况,结果表明当烧结温度为1700℃、保温时间为10main或15min、烧结压力为32MPa时,模拟结果的晶粒粒径与尺寸分布良好,能够获得较好的烧结体微观组织结构。与同样工艺下实际烧结制备的Al2O3/TiN陶瓷刀具材料对比发现,烧结体中基体及二相粒子的粒径以及二相粒子的分布情况与用元胞自动机方法模拟的结果吻合。
对Al2O3/TiN两相陶瓷刀具材料的元胞自动机模型进行了拓展,考虑随机分布的烧结助剂的影响,建立了含有烧结助剂的Al2O3/TiN复相陶瓷刀具材料的元胞自动机模型并进行了模拟,结果表明添加烧结助剂对细化晶粒有着明显的作用。考虑陶瓷刀具材料烧结致密化过程的情况,建立了含有气孔的Al2O3/TiN复相陶瓷刀具材料的元胞自动机模型,进行了陶瓷刀具材料烧结致密化过程的模拟,分析了同时含有烧结助剂和气孔情况下的晶粒生长情况,结果表明烧结助剂能够有效提高陶瓷刀具材料烧结体的致密度。与实际烧结制备的Al2O3/TiN复相陶瓷刀具材料对比发现,烧结体中基体、二相粒子、烧结助剂和气孔的分布情况与用元胞自动机方法模拟的结果十分吻合。
以元胞自动机模拟研究结果为指导,制备了Al2O3/TiN复相陶瓷刀具材料,结果表明当烧结温度为1700℃、保温时间为10min、烧结压力为32MPa时,TiN体积含量为50%的Al2O3/TiN复相陶瓷刀具材料有最佳综合力学性能。在此基础上成功制备了Al2O3/Ti(C,N)基复合陶瓷刀具材料ATCN50b,当烧结温度为1700℃、烧结压力32MPa、保温时间10min时,ATCN50b材料获得最佳综合力学性能,其抗弯强度为910MPa、维氏硬度为20.5GPa、断裂韧性为8.11MPa·m1/2。
研究了ATCN50b刀具连续切削1Cr13马氏体不锈钢的切削性能,并与原山东工业大学研制的商用SG-4、LT55复合陶瓷刀具、山东大学研制的AWT10、 A60W4T6、WZ10A复合刀具材料及商用YG8、YT5、TW1硬质合会刀具的切削性能进行了对比研究。在切削深度ap=0.1mm、进给量f=0.1mm/r、切削速度v=100m/min的切削参数下,ATCN50b刀具获得最长切削寿命61min,满足精加工的表面粗糙度要求,刀具寿命是YG8硬质合金刀具寿命的116%,是LT55和SG-4陶瓷刀具寿命的122%,是YW1硬质合金刀具寿命的129%,并且远高于其它对比刀具。在切削速度v=260m/min的切削参数下,ATCN50b刀具寿命接近30min,满足精加工的表面粗糙度要求。刀具寿命是LT55陶瓷刀具寿命的120%,是SG-4陶瓷刀具和YT15硬质合金刀具寿命的129%,并远高于其它对比刀具。研究了ATCN50b刀具的磨损破损形态和主要磨损和破损机理,结果表明,虽然刀具表面有一定的粘结现象发生,但ATCN50b刀具的高温稳定性还是较好的,适合于高效加工1Cr13马氏体不锈钢。
Ceramic tool materials have high hardness, high abrasion resistance and high stability in high temperature, it is suitable for high efficient cutting of the hard cutting materials. The developed method of the existing ceramic tool materials is experiment, which can cause to the bad design. Especially there are no systematic guidance to the sintering process microstructure design and optimization, there are no theories guidance for the new ceramic tool materials development, and it is difficult to obtain good mechanical properties.
In this paper, using the cellular automata model, considering the two phase particles, sintering additives and sintering densification process, the main parameters including holding time, sintering temperature, sintering pressure are coupled into the cellular automata model. The grain growth process of Al2O3/TiN composite ceramic tool material sintering process is simulated. Finally the analysis process is validated through the sintering experiment, the results show that the simulation results and the experimental results are in good agreement with the actual sintering. This theory combining with experiment, the ATN50material is developed, and the ATCN50b composite ceramic tool materials are developed successfully. The high efficient cutting experimental studies of1Cr13stainless steel are processed. The results show that the cutting tool life and the surface roughness of the workpiece are superior to the existing several kinds of composite ceramic cutting tools and carbide cutting tools under high speed.
The maximum grain orientation has an important impact on simulation process and result. The maximum grain orientation has been given, and the main parameters including holding time, sintering temperature, and sintering pressure are coupled into the cellular automata model. The grain growth simulation model for ceramic material sintering process based on cellular automaton is constructed based on the grain growth driving force theory of grain boundary energy and the curvature of the grain boundary. The ceramic tool materials sintering process of microstructure evolution are simulated. The results show that when the sintering temperature is1700℃, holding time is10min or15min, sintering pressure is32MPa, the simulation results of grain size and size distribution are good, the better sinter microstructur can obtained e. Contrasting the same process actual sintering preparation of Al2O3/TiN ceramic tool material with simulation results, sintered body of matrix, second phase particle size and the second phase particle distributionare consistent with cellular automaton method simulation results.
Considering the impact of random distribution of sintering additives, based on Al2O3/TiN two-phase ceramic tool materials, the cellular automata model Al2O3/TiN composite ceramic tool material with sintering additives is established. The results show that sintering additives has obvious effect on grain refinement. Considering sintering densification process of ceramic tool materials, the cellular automata model of Al2O3/TiN composite ceramic tool material containing pores is established. Comparing the grain growth condition without hole with with hole, the results show that sintering additives can improve the ceramic sintered body density effectively. Contrasting the same process actual sintering preparation of Al2O3/TiN ceramic tool material with simulation results, sintered body of matrix, second phase particle size, sintering additives and hole distribution are consistent with the cellular automaton method simulation results.
In the guidance of cellular automata simulation results, the Al2O3/TiN composite ceramic tool materials are prepared, the results show that when the sintering temperature is1700℃, holding time is10min, sintering pressure is32MPa, TiN volume content is50%, Al2O3/TiN composite ceramic tool material has the best comprehensive mechanical properties. On this basis, the Al2O3/Ti(C,N) composite ceramic tool material ATCN50b is prepared successfully. When the sintering temperature is1700℃, sintering pressure is32MPa, holding time is10min, ATCN50b materials obtain the best mechanical properties, the bending strength is910MPa, Vickers hardness is20.5GPa and fracture toughness is8.11MPa·m1/2.
The cutting performance of ATCN50b ceramic tool cutting1Cr13martensitic stainless steel is studied, and is compared with the commercial SG-4, LT55composite ceramic tool that developed by the former Shandong University of Technology, AWT10A60W4T6, WZ10A composite tool materials that are developed by Shandong University and the commercial YG8, YT5, TW1carbide tool. When cutting depth ap is0.1mm, feed rate f is0.1mm/r, cutting speed v is100m/min, ATCN50b has the longest service life61min, meets the machining surface roughness requirements, the life is of116%YG8hard alloy tool, is122%of LT55and SG-4tool, is129%of YW1tool, and far higher than other tools. When the cutting speed v is260m/min, ATCN50b has the service life of30min, and meet the machining surface roughness requirements, the life is120%of LT55tool; is129%of SG-4tool and YT15tool, and far higher than other tools. The wear and failure form, the main wear and breakage mechanism of ATCN50b tool are studied. The results show that the ATCN50b tool high temperature stability is good and suitable for high efficient processing of1Cr13martensitic stainless steel, though the tool surface has a certain bond phenomenon.
本文利用元胞自动机模型,考虑了二相粒子、烧结助剂和烧结致密化过程,将烧结过程的主要参数保温时间、烧结温度、烧结压力耦合进元胞自动机模型,进行了Al2O3/TiN复相陶瓷刀具材料烧结过程的模拟,最后通过烧结实验验证了理论分析,结果表明模拟分析的结果与实际烧结实验结果符合很好。以此理论研究为指导结合实验研制了ATN50材料,并在其基础上研制成功了ATCN50b复合陶瓷刀具材料。利用ATCN50b陶瓷刀具进行了高效切削1Crl3马氏体不锈钢的性能研究,结果表明,在高速下刀具寿命和工件加工的表面粗糙度都优于现有的几种复合陶瓷刀具和常用硬质合金刀具。
对元胞自动机算法进行了研究,确定了最大取向值对模拟结果的影响,考虑到实际烧结过程中主要参数的影响,将烧结时的保温时间、烧结温度、烧结压力耦合进了元胞自动机模型。基于晶界能与晶界曲率的变化的理论,建立了耦合实际烧结过程主要参数的两相陶瓷刀具材料的元胞自动机模型,实现了Al2O3/TiN两相陶瓷刀具材料烧结过程微观组织结构演变的模拟。研究了烧结过程中的晶粒生长情况,结果表明当烧结温度为1700℃、保温时间为10main或15min、烧结压力为32MPa时,模拟结果的晶粒粒径与尺寸分布良好,能够获得较好的烧结体微观组织结构。与同样工艺下实际烧结制备的Al2O3/TiN陶瓷刀具材料对比发现,烧结体中基体及二相粒子的粒径以及二相粒子的分布情况与用元胞自动机方法模拟的结果吻合。
对Al2O3/TiN两相陶瓷刀具材料的元胞自动机模型进行了拓展,考虑随机分布的烧结助剂的影响,建立了含有烧结助剂的Al2O3/TiN复相陶瓷刀具材料的元胞自动机模型并进行了模拟,结果表明添加烧结助剂对细化晶粒有着明显的作用。考虑陶瓷刀具材料烧结致密化过程的情况,建立了含有气孔的Al2O3/TiN复相陶瓷刀具材料的元胞自动机模型,进行了陶瓷刀具材料烧结致密化过程的模拟,分析了同时含有烧结助剂和气孔情况下的晶粒生长情况,结果表明烧结助剂能够有效提高陶瓷刀具材料烧结体的致密度。与实际烧结制备的Al2O3/TiN复相陶瓷刀具材料对比发现,烧结体中基体、二相粒子、烧结助剂和气孔的分布情况与用元胞自动机方法模拟的结果十分吻合。
以元胞自动机模拟研究结果为指导,制备了Al2O3/TiN复相陶瓷刀具材料,结果表明当烧结温度为1700℃、保温时间为10min、烧结压力为32MPa时,TiN体积含量为50%的Al2O3/TiN复相陶瓷刀具材料有最佳综合力学性能。在此基础上成功制备了Al2O3/Ti(C,N)基复合陶瓷刀具材料ATCN50b,当烧结温度为1700℃、烧结压力32MPa、保温时间10min时,ATCN50b材料获得最佳综合力学性能,其抗弯强度为910MPa、维氏硬度为20.5GPa、断裂韧性为8.11MPa·m1/2。
研究了ATCN50b刀具连续切削1Cr13马氏体不锈钢的切削性能,并与原山东工业大学研制的商用SG-4、LT55复合陶瓷刀具、山东大学研制的AWT10、 A60W4T6、WZ10A复合刀具材料及商用YG8、YT5、TW1硬质合会刀具的切削性能进行了对比研究。在切削深度ap=0.1mm、进给量f=0.1mm/r、切削速度v=100m/min的切削参数下,ATCN50b刀具获得最长切削寿命61min,满足精加工的表面粗糙度要求,刀具寿命是YG8硬质合金刀具寿命的116%,是LT55和SG-4陶瓷刀具寿命的122%,是YW1硬质合金刀具寿命的129%,并且远高于其它对比刀具。在切削速度v=260m/min的切削参数下,ATCN50b刀具寿命接近30min,满足精加工的表面粗糙度要求。刀具寿命是LT55陶瓷刀具寿命的120%,是SG-4陶瓷刀具和YT15硬质合金刀具寿命的129%,并远高于其它对比刀具。研究了ATCN50b刀具的磨损破损形态和主要磨损和破损机理,结果表明,虽然刀具表面有一定的粘结现象发生,但ATCN50b刀具的高温稳定性还是较好的,适合于高效加工1Cr13马氏体不锈钢。
Ceramic tool materials have high hardness, high abrasion resistance and high stability in high temperature, it is suitable for high efficient cutting of the hard cutting materials. The developed method of the existing ceramic tool materials is experiment, which can cause to the bad design. Especially there are no systematic guidance to the sintering process microstructure design and optimization, there are no theories guidance for the new ceramic tool materials development, and it is difficult to obtain good mechanical properties.
In this paper, using the cellular automata model, considering the two phase particles, sintering additives and sintering densification process, the main parameters including holding time, sintering temperature, sintering pressure are coupled into the cellular automata model. The grain growth process of Al2O3/TiN composite ceramic tool material sintering process is simulated. Finally the analysis process is validated through the sintering experiment, the results show that the simulation results and the experimental results are in good agreement with the actual sintering. This theory combining with experiment, the ATN50material is developed, and the ATCN50b composite ceramic tool materials are developed successfully. The high efficient cutting experimental studies of1Cr13stainless steel are processed. The results show that the cutting tool life and the surface roughness of the workpiece are superior to the existing several kinds of composite ceramic cutting tools and carbide cutting tools under high speed.
The maximum grain orientation has an important impact on simulation process and result. The maximum grain orientation has been given, and the main parameters including holding time, sintering temperature, and sintering pressure are coupled into the cellular automata model. The grain growth simulation model for ceramic material sintering process based on cellular automaton is constructed based on the grain growth driving force theory of grain boundary energy and the curvature of the grain boundary. The ceramic tool materials sintering process of microstructure evolution are simulated. The results show that when the sintering temperature is1700℃, holding time is10min or15min, sintering pressure is32MPa, the simulation results of grain size and size distribution are good, the better sinter microstructur can obtained e. Contrasting the same process actual sintering preparation of Al2O3/TiN ceramic tool material with simulation results, sintered body of matrix, second phase particle size and the second phase particle distributionare consistent with cellular automaton method simulation results.
Considering the impact of random distribution of sintering additives, based on Al2O3/TiN two-phase ceramic tool materials, the cellular automata model Al2O3/TiN composite ceramic tool material with sintering additives is established. The results show that sintering additives has obvious effect on grain refinement. Considering sintering densification process of ceramic tool materials, the cellular automata model of Al2O3/TiN composite ceramic tool material containing pores is established. Comparing the grain growth condition without hole with with hole, the results show that sintering additives can improve the ceramic sintered body density effectively. Contrasting the same process actual sintering preparation of Al2O3/TiN ceramic tool material with simulation results, sintered body of matrix, second phase particle size, sintering additives and hole distribution are consistent with the cellular automaton method simulation results.
In the guidance of cellular automata simulation results, the Al2O3/TiN composite ceramic tool materials are prepared, the results show that when the sintering temperature is1700℃, holding time is10min, sintering pressure is32MPa, TiN volume content is50%, Al2O3/TiN composite ceramic tool material has the best comprehensive mechanical properties. On this basis, the Al2O3/Ti(C,N) composite ceramic tool material ATCN50b is prepared successfully. When the sintering temperature is1700℃, sintering pressure is32MPa, holding time is10min, ATCN50b materials obtain the best mechanical properties, the bending strength is910MPa, Vickers hardness is20.5GPa and fracture toughness is8.11MPa·m1/2.
The cutting performance of ATCN50b ceramic tool cutting1Cr13martensitic stainless steel is studied, and is compared with the commercial SG-4, LT55composite ceramic tool that developed by the former Shandong University of Technology, AWT10A60W4T6, WZ10A composite tool materials that are developed by Shandong University and the commercial YG8, YT5, TW1carbide tool. When cutting depth ap is0.1mm, feed rate f is0.1mm/r, cutting speed v is100m/min, ATCN50b has the longest service life61min, meets the machining surface roughness requirements, the life is of116%YG8hard alloy tool, is122%of LT55and SG-4tool, is129%of YW1tool, and far higher than other tools. When the cutting speed v is260m/min, ATCN50b has the service life of30min, and meet the machining surface roughness requirements, the life is120%of LT55tool; is129%of SG-4tool and YT15tool, and far higher than other tools. The wear and failure form, the main wear and breakage mechanism of ATCN50b tool are studied. The results show that the ATCN50b tool high temperature stability is good and suitable for high efficient processing of1Cr13martensitic stainless steel, though the tool surface has a certain bond phenomenon.
引文
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