新型刀具材料——陶瓷

介绍了陶瓷刀具材料的种类和发展过程、陶瓷刀具材料的性能和应用范围，并列入一些切削试验数据。     

金属陶瓷材料异军突起 切削加工刀具挑战未来

陶瓷刀具是现代金属切削加工中的一种新型材料刀具。传统硬合金刀具材料的耐磨性和刃口的锋利程度很难同时满足工件的小尺寸公差、高表面质量和高生产效率的要求,选用金属陶瓷刀具是解决这一难题最直接和有效的方法。笔者针对金属陶瓷刀具的性能特点及功用,分析了金属陶瓷刀具磨损的原因及对机床的要求,提出了金属陶瓷刀的发展是切削加工领域的又一次革命,同时指出了新型金属陶瓷材料刀具推动现代切削加工技术的快速发展。     

新型陶瓷刀具

刀具的性能是影响切削加工效率、精度、表面质量等的决定性因素之一。在现代化加工过程中，提高加工效率的最有效方法是采用高速切削加工技术；随着现代科学技术和生产的发展，越来越多地采用超硬难加工材料，以提高机器设备的使用寿命和工作性能。而陶瓷刀具则以其优异的耐热性、耐磨性和化学稳定性，在高速切削领域和难加工材料方面显示了传统刀具无法比拟的优势。新型陶瓷刀具更由于有很高的硬度（HRA93～95），从而可加工硬度高达HRC65的各类难加工材料，免除退火加工所消耗的电力和时间；可提高工件硬度，延长机器设备的使用寿命。陶瓷刀具的主要原料Al、O和Si是地壳中最丰富的成分，可以说是取之不尽，用之不竭的，因此新型陶瓷刀具的应用前景十分广阔。     

陶瓷刀具材料及应用技术

陶瓷刀具具有优良的切削性能，在金属切削加工中越来越受到重视。本文对陶瓷刀具的种类、性能和应用进行了论述，并指出陶瓷刀具材料的发展方向。     

新型陶瓷刀具材料的发展趋势

新型陶瓷刀具的出现,是人类首次通过运用陶瓷材料改革机械切削加工的一场技术革命的成果。陶瓷材料因其高硬度与耐高温特性成为新一代的刀具材料,但也由于脆性受到局限。于是克服陶瓷刀具材料的脆性,提高其韧性,成为近百年来陶瓷刀具研究的主要课题。     

浅析陶瓷刀具高速切削可靠性的影响因素

简要介绍了影响陶瓷刀具高速切削可靠性的几种因素，阐明了陶瓷刀具与被加工材料的匹配性要求和陶瓷刀具几何角度的选择，以充分发挥陶瓷刀具的工效高、使用寿命长和加工质量好等优点。     

新型陶瓷刀具材料的研究与开发

工业用钢材的质量提高使材料加工难度增加,耐高温的高硬度高强度陶瓷材料被用做切削刀具并逐渐推广应用。本文对陶瓷刀具的材质、种类、性能特点作了比较和评价,并重点介绍了新型的晶须增韧陶瓷刀具。最后,对陶瓷刀具的市场前景进行了预测,并指出了陶瓷刀具研制方面应该深入研究的课题。     

全球切削刀具新材料和涂层技术现状

近代金属切削刀具材料从碳素工具钢、高速钢发展到今日的硬质合金、涂层硬质合金、陶瓷、立方氮化硼等超硬刀具材料,使切削速度从每分钟几米飚升到千米乃至万米。随着数控机床和难加工材料的不断发展,刀具实有难以招架之势。要实现高速切削、干切削、硬切削必须有好的刀具材料。在影响金属切削发展的诸多因素中,刀具材料起着决定性作用。     

陶瓷刀具的种类及发展趋势

本文主要研究陶瓷刀具的种类,应用以及发展前景,并简单介绍了陶瓷刀具的发展背景。随着新技术革命的发展,要求不断的提高切削加工的生产率并且降低生产成本,特别是数控机床的发展,要求开发比硬质合金刀具切速更高、更耐磨的新型刀具。其次,现在国际上硬质合金产量已经达到了20000—25000t。每年所消耗的大量金属,比如W、Co、Ta以及Nb等等。这些金属的矿产资源正在减少,价格也在上涨,按照目前的消耗速度来看,不到几十年,有些资源便会被耗尽。陶瓷刀具便是在这样的背景下发展起来的。     

新型陶瓷刀具的切削性能研究

本文研究了山东工业大学机械工程学院研制的新型陶瓷刀具材料（包括ＪＸ－２，Ｈ５，Ｈ１３和Ｈ２１等）分别切削铸铁（ＨＴ２０）淬火４５号钢和难加工材料ＧＨ９９时的切削性能，探讨了各陶瓷刀具的抗磨损能力，实验研究了切削速度和进给量对刀具磨损的影响，并对切削条件进行了优化。     

A critical review on self-lubricating ceramic-composite cutting tools

Self-lubricating ceramic cutting tools have recently gained considerable attention as the tool wear in cutting hard-to-cut materials greatly affects the production cost, integrity of the machined surface, and productivity. In an attempt to compile the progress made in this important research area, a critical review has been performed covering a range of aspects. These include the current research trends and the need for self-lubricating ceramic tools, identification of prospective high-temperature solid lubricants and their limitations followed by a presentation of recent experimental and numerical work conducted related to self-lubricant ceramic cutting tools. Various lubrication mechanisms involved in the cutting process are also examined to identify general tribological response under various tribo-systems, which is expected to provide useful directions for the researchers and cutting industry. The current and emerging synthesis techniques are discussed in detail and compared with respect to ceramic cutting tools. Finally, some research gaps and future directions are suggested that could lead to optimum design and development of innovative self-lubricating ceramic tools.     

低碳经济驱动新型陶瓷材料行业的未来

新型陶瓷材料具有高强度、高硬度、耐腐蚀、耐高温等特性。近些年来,在开发新能源和有效利用石油能源的呼声中,发达国家相继掀起了新型陶瓷材料研究开发的热潮。针对新型陶瓷材料的独特性能,综述了工程陶瓷材料用途广泛和功能陶瓷材料的应用前景,以及陶瓷基复合材料的发展趋势;介绍了广泛应用于工程领域的陶瓷阀门材料和切削性能优良的新型陶瓷刀具,同时指出了陶瓷材料产业的应用开发趋势。     

低碳经济驱动新型陶瓷材料行业的未来

新型陶瓷材料具有高强、高硬、耐腐蚀、耐高温等特性。近些年来,在开发新能源和有效利用石油能源的呼声中,发达国家相继掀起了新型陶瓷材料研究开发的热潮。针对新型陶瓷材料的独特性能,综述了工程陶瓷材料用途广泛和特殊性能的功能陶瓷材料广阔应用前景;以及陶瓷基复合材料具有广泛的发展趋势;介绍了广泛应用于工程领域的陶瓷阀门材料和切削性能优良的新型陶瓷刀具;同时指出了陶瓷材料产业的应用开发趋势。     

新型梯度功能陶瓷刀具材料的设计模型

本文首次提出对陶瓷刀具材料的组成分布，微观结构进行设计以形成梯度模型，通过不同组成分布的刀具工作过程中的热应力，机械应力及材料制备过程中的残余热应力进行了模拟，以使刀具材料内部形成与外载应力部分抵消的机制，从而提高陶瓷刀具抗磨损破损的性能。     

Investigation of novel multiscale textures for the enhancement of the cutting performance of Al2O3/TiC ceramic cutting tools

Currently, the high temperature and severe friction conditions at the tool-chip interface are the main reasons for ceramic tool wear failures. Surface texturing as a geometric extension for cutting tools is a promising way to extend their service life. In this study, a novel type of multiscale texture was developed, and its effect on the cutting performance of an Al₂O₃/TiC ceramic cutting tool while machining AISI H13 steel was explored in a conventional cooling environment. The cutting force, cutting temperature, and tool wear morphology were investigated at cutting velocities ranging from 80 to 249 m/min. Microgroove textured Al₂O₃/TiC ceramic tools were prepared for comparison. The results show that the structure of the multiscale textures maintained good integrity over the range of cutting velocities. Thus, the synergistic effect of the microscale and nanoscale textures promoted the introduction and permeation of the cutting fluid. Therefore, the multiscale textures effectively enhanced the cutting performance of the Al₂O₃/TiC ceramic tools.     

Microstructure design and preparation of Al2O3/TiC/TiN micro-nano-composite ceramic tool materials based on properties prediction with finite element method

The objective of this paper was to improve the accuracy of semi-empirical method used to design ceramic cutting tool materials. The mechanical properties were predicted by employing finite element model of material microstructure, so as to design microstructure and prepare new ceramic materials. Based on the Voronoi and randomness method, the microstructure model representing the complexity and randomness of micro-nano-composite ceramic material microstructure was established. Combining the representative volume element (RVE) of ceramic material microstructure with mechanical tests, the simulations of mechanical tests were conducted to acquire the flexure strength, fracture toughness and hardness of materials. The microstructure models with various parameters were designed and the material properties were predicted to determine the optimal microstructure parameters. Then, The ceramic cutting tool materials possessing the optimal microstructure parameters were developed for machining ultra-high strength steels. The results showed that the mechanical properties of ceramic materials first improved and then declined as the nano-scale TiC volume fraction increased. To obtain the best comprehensive mechanical properties, the contents of micro-scale TiN, TiC and nano-scale TiC were set as 20%, 10% and 10%, respectively. The prepared ceramic materials possessed the flexure strength of 881.4 MPa, the fracture toughness of 7.8 MPa m^1/2, and the Vickers hardness of 20.8 GPa. This research is beneficial to the development of cutting tool design theory and the improvement of the tool life.     

陶瓷刀具材料的现状与发展

本文阐述了陶瓷刀具材料的发展现状 ,着重论述了氧化铝系陶瓷和氮化硅系陶瓷材料技术。对陶瓷刀具材料的发展趋势进行了综述。指出超微粉刀具、复相陶瓷刀具、涂层刀具及金属陶瓷是陶瓷刀具材料的研究方向。     

现代陶瓷刀具材料的发展

刀具材料的发展经历了工具钢、高速钢、金属陶瓷、陶瓷和超硬材料五个阶段,精密加工脆性和高硬度的材料促进了刀具材料的不断发展。     

人工神经网络在Al2O3/TiC/SiC多相陶瓷刀具材料开发中的应用

复相陶瓷刀具材料应用前景广阔。利用基于BP算法的人工神经网络技术,建立了预测颗粒增韧多相陶瓷刀具材料各组分体积百分含量的预测模型,模型应结合材料性能合理确定输入参数。利用该模型实际开发了Al2O3/TiC/SiC系复相陶瓷刀具材料,材料的力学性能满足要求。