Design, preparation and mechanical properties of microwave sintered TiB2-based ceramic tools with complex edge shape
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摘要: 基于微波烧结的特点,设计了复杂刃形TiB2基陶瓷刀具的结构参数。利用有限元仿真,研究了在车削球墨铸铁QT450时刀具结构参数对车削力和车削温度的影响。确定了复杂刃形TiB2基陶瓷刀具的最优刀具前角为5°、后角为6°、刀尖圆弧半径为0.8 mm。采用微波烧结技术制备了复杂刃形TiB2基陶瓷刀具,研究了压制压力和保压时间对复杂刃形TiB2基陶瓷刀具的相对密度、力学性能和微观组织的影响。结果表明:压制压力对晶粒的异常生长影响较大,合理的压制压力可以抑制晶粒的异常长大,改善刀具断裂模式,进而提高刀具性能。合理的保压时间可以使刀具表面的白色相分布均匀,防止聚集,这有利于刀具断裂韧度的提高。在压制压力为200 MPa,保压时间为4 min时,刀具各部位尺寸收缩率较为平均,成形精度较高,致密度最高,微观组织更加均匀,晶粒排列更加紧密,综合力学性能最优。Abstract: The structural parameters of TiB2-based ceramic tools with complex edge shapes were designed based on microwave sintering characteristics. The effect of tool design parameters on turning forces and temperatures when turning QT450 ductile cast iron was investigated using finite element simulation. For TiB2-based ceramic tools with complex cutting edges, the optimum tool front angle was found to be 5°, the optimum back angle was found to be 6° and the optimum tip radius was found to be 0.8 mm. Complex edge-shaped TiB2-based ceramic tools were prepared by microwave sintering technology, and the effects of pressing pressure and holding time on the relative density, mechanical properties and microstructure of complex edge-shaped TiB2-based ceramic tools were investigated. The results show that the pressing pressure has a great influence on the abnormal growth of grains, and a reasonable pressing pressure can inhibit the abnormal growth of grains, improve the tool fracture mode, and then improve the tool performance. A reasonable holding time can make the white phase on the surface of the tool partition uniform and prevent aggregation, which is conducive to improving the fracture toughness of the tool. When the pressing pressure is 200 MPa and the holding time is 4 min, the dimensional shrinkage of each part of the tool is more average, the forming accuracy is higher, the densification is the highest, the microstructure is more uniform, the grain arrangement is more compact, and the overall mechanical properties are optimal.
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Key words:
- tool structure /
- microwave sintering /
- pressing pressure /
- holding time /
- mechanical property
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表 1 复杂刃形TiB2基陶瓷刀具车削仿真结构参数设计
Table 1. Structural parameter design for turning simulation of TiB2-based ceramic tools with complex edge shape
Research objective Tool front angle γ0/(°) Tool back angle α0/(°) Tool tip arc radius r/mm Design parameter −5, 0, 5, 10, 15 0, 3, 6, 9, 12 0.4, 0.6, 0.8, 1.0, 1.2 表 2 复杂刃形TiB2基陶瓷刀具原材料及特性
Table 2. Raw materials and characteristics of TiB2-based ceramic tools with complex cutting edges
Powder composition Density/(g·cm−3) Particle size/μm Purity/% Manufacturer TiB2 4.502 0.5 99.9 Shanghai Chaowei TiC 4.930 0.5 99.9 Shanghai Chaowei HfC 12.700 0.1 99.9 Shanghai Chaowei Ni 8.902 0.6 99.9 Shanghai Chaowei Mo 10.200 0.5 99.9 Shanghai Chaowei 表 3 不同压制压力下复杂刃形TiB2基陶瓷刀具试样烧结前后尺寸和收缩率
Table 3. Dimensions and shrinkage of TiB2-based ceramic cutting tool samples before and after sintering at different press pressures
Blade sample Pre-sintering After sintering Percentage of
contraction/%Blade sample A (2 min, 150 MPa) Knife blade/mm 3.30 2.80 15.15 Thickness/mm 5.70 4.80 15.79 Length of side/mm 15.50 12.70 18.06 Volumetric/mm3 592.98 335.24 43.47 Blade sample B (2 min, 200 MPa) Knife blade/mm 3.30 2.70 18.18 Thickness/mm 5.50 4.40 20.00 Length of side/mm 15.50 12.92 16.64 Volumetric/mm3 572.17 318.04 44.42 Blade sample C (2 min, 250 MPa) Knife blade/mm 3.30 2.80 15.15 Thickness/mm 5.50 4.52 17.82 Length of side/mm 15.50 12.90 16.77 Volumetric/mm3 572.17 325.70 43.08 Blade sample D (2 min, 300 MPa) Knife blade/mm 3.30 2.80 15.15 Thickness/mm 5.30 4.50 15.09 Length of side/mm 15.50 13.14 15.23 Volumetric/mm3 551.37 336.44 38.98 表 4 不同压制压力下复杂刃形TiB2基陶瓷刀具试样烧结前后的结构尺寸及误差
Table 4. Structural dimensions and errors of TiB2-based ceramic tool specimens with complex cutting edges before and after sintering under different pressing pressures
Blade sample Pre-sintering After sintering Errors/% Blade sample A (2 min, 150 MPa) Rake angle/(°) 5.00 5.55 11.00 Tool tip arc radius/mm 0.80 0.61 23.75 Blade sample B (2 min, 200 MPa) Rake angle/(°) 5.00 5.35 7.00 Tool tip arc radius/mm 0.80 0.68 15.00 Blade sample C (2 min, 250 MPa) Rake angle/(°) 5.00 5.65 13.00 Tool tip arc radius/mm 0.80 0.66 17.50 Blade sample D (2 min, 300 MPa) Rake angle/(°) 5.00 5.65 13.00 Tool tip arc radius/mm 0.80 0.64 20.00 Test point Element/wt% B C Ti Hf Ni Mo A 54.46 39.86 3.49 0.91 1.24 0.05 B 60.84 21.42 15.39 1.11 1.25 0.00 C 21.84 32.16 32.73 13.24 0.02 0.01 D 54.44 37.53 7.80 0.01 0.03 0.19 E 25.39 42.18 24.16 1.39 6.86 0.01 F 10.85 38.55 10.24 40.36 0.01 0.00 表 6 不同保压时间下复杂刃形TiB2基陶瓷刀具试样烧结前后尺寸和收缩率
Table 6. Dimensions and shrinkage of TiB2-based ceramic cutting tool samples before and after sintering at different pressure holding time
Blade sample Pre-sintering After sintering Percentage of contraction/% Blade sample B1 (2 min, 200 MPa) Knife blade/mm 3.30 2.70 18.18 Thickness/mm 5.50 4.40 20.00 Length of side/mm 15.50 12.92 16.64 Volumetric/mm3 572.17 318.04 44.42 Blade sample B2 (4 min, 200 MPa) Knife blade/mm 3.30 2.74 16.97 Thickness/mm 5.70 4.75 16.67 Length of side/mm 15.50 12.82 17.29 Volumetric/mm3 592.98 338.04 42.99 Blade sample B3 (6 min, 200 MPa) Knife blade/mm 3.30 2.80 15.15 Thickness/mm 5.40 4.43 17.96 Length of side/mm 15.50 12.85 17.10 Volumetric/mm3 561.77 316.75 43.62 Blade sample B4 (8 min, 200 MPa) Knife blade/mm 3.30 The specimen cracked in two parts and could not be tested Thickness/mm 5.30 Length of side/mm 15.50 Volumetric/mm3 551.37 表 7 不同保压时间下复杂刃形TiB2基陶瓷刀具试样烧结前后的结构尺寸及误差
Table 7. Structural dimensions and errors of TiB2-based ceramic tool specimens with complex cutting edge shape before and after sintering at different pressure holding time
Blade sample Pre-sintering After sintering Error/% Blade sample B1 (2 min, 200 MPa) Rake angle/(°) 5.00 5.35 7.00 Tool tip arc radius/mm 0.80 0.68 15.00 Blade sample B2 (4 min, 200 MPa) Rake angle/(°) 5.00 5.37 7.40 Tool tip arc radius/mm 0.80 0.69 13.75 Blade sample B3 (6 min, 200 MPa) Rake angle/(°) 5.00 5.45 9.00 Tool tip arc radius/mm 0.80 0.69 13.75 Blade sample B4 (8 min, 200 MPa) Rake angle/(°) 5.00 3.50 30.00 Tool tip arc radius/mm 0.80 0.61 23.75 -
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