CN111098392A - Manufacturing method of large-size ceramic part with complex surface - Google Patents

Manufacturing method of large-size ceramic part with complex surface Download PDF

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Publication number
CN111098392A
CN111098392A CN202010019246.9A CN202010019246A CN111098392A CN 111098392 A CN111098392 A CN 111098392A CN 202010019246 A CN202010019246 A CN 202010019246A CN 111098392 A CN111098392 A CN 111098392A
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China
Prior art keywords
ceramic
green body
ceramic green
complex
minimum
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CN202010019246.9A
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Chinese (zh)
Inventor
邹斌
王鑫锋
邢宏宇
王鹏
黄传真
姚鹏
史振宇
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Shandong University
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Shandong University
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Priority to CN202010019246.9A priority Critical patent/CN111098392A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24BMACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B1/00Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28DWORKING STONE OR STONE-LIKE MATERIALS
    • B28D1/00Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mining & Mineral Resources (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)

Abstract

The invention relates to a manufacturing method of a large-size complex-surface ceramic part, which comprises the following steps of pressing a ceramic blank meeting the allowance of a set size according to the size of a target part, wherein the shape of the ceramic blank is required to be determined before pressing, the required volume when the ceramic blank forms a minimum cylinder enveloping the target part is set as a first numerical value, and the required volume when the ceramic blank forms a minimum cuboid enveloping the target part is set as a second numerical value; taking the shape corresponding to the smaller one of the first numerical value and the second numerical value to complete the pressing of the ceramic green body; if the ceramic green body is a cylinder, processing the ceramic green body into a minimum cylinder step shaft enveloping the target part in a turning mode; if the ceramic green body is a cuboid, processing the ceramic green body into a minimum enveloping body structure enveloping the target part by adopting a milling method; sintering the preprocessed ceramic green body to obtain a ceramic part; and finally finishing the fine reference and the external profile processing.

Description

Manufacturing method of large-size ceramic part with complex surface
Technical Field
The invention belongs to the technical field of ceramic processing, and particularly relates to a manufacturing method of a large-size ceramic part with a complex shape surface.
Background
The ceramic material has the characteristics of high hardness, high brittleness and low fracture toughness, so that the surface processing, particularly the processing of a curved surface, of the sintered and molded ceramic material is very difficult. The common ceramic processing methods at present comprise traditional machining, ultrasonic processing, electric processing, laser processing and grinding processing.
The traditional machining refers to turning by using a superhard cutter, and the phenomenon that the cutter is damaged easily due to serious cutting heat in the cutting process is easily caused; during the processing, the ceramic material is easy to generate defects such as pits, openings and cracks on the surface under the action of cutting force; and the cutting amount is usually small due to the limitation of the cutter, so that the processing efficiency is extremely low. However, the processing methods such as ultrasonic processing, electric processing, laser processing, and grinding have respective limitations, for example, the application range is small, and defects are easily generated on the surface of the ceramic. It is known that it is very difficult to complete the outer surface shape of the ceramic, especially the processing of curved surfaces, by removing material after the ceramic green body is sintered.
Therefore, under the condition of meeting the machining allowance, when the ceramic green blank is pressed, the ceramic green blank is made to fit the shape of the target part as much as possible, so that the material removal amount of the surface of the sintered ceramic part is reduced, and the machining difficulty is reduced.
The forming process of the ceramic green body before firing mainly comprises dry forming and wet forming, and the traditional wet forming process such as tape casting, gel injection molding, injection molding and the like can realize the forming of complex ceramic parts to a certain extent. However, gel casting and injection molding processes require special molds, are high in cost and are not suitable for small-batch individual production. Although the casting forming process can manufacture parts with complex shapes by laminating casting sheets layer by layer, the process is complicated, the step effect of the prepared parts is obvious, and the surface quality of the parts is greatly reduced.
Therefore, when a ceramic blank having the same shape as the target part and a size satisfying the design margin is obtained from the blank, the problems of excessive cost and complicated molding steps occur, and the method is not suitable for small-batch or customized production of ceramic parts.
The inventor thinks that the ceramic green body has the problems of reducing production cost and process steps and difficult control of deformation after sintering during the forming of the ceramic green body, so that the ceramic green body cannot be accurately fitted with the shape and the size of a target part. When the sintered ceramic blank is processed, in order to reduce the material removal amount, the ceramic blank needs to be accurately fitted with the shape and size of a target part. In summary, in different stages of ceramic manufacturing, there are different requirements for the shape and size of the ceramic blank, which causes technical contradiction and makes it difficult to achieve balance between the two.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method for manufacturing a large-size ceramic part with a complex profile, which can solve the technical contradiction between the requirements on the shape and the size of a ceramic green body by reducing different working procedures before and after sintering of ceramic.
In order to achieve the purpose, the invention adopts the following technical scheme: a method for manufacturing a large-size complex-shaped surface ceramic part comprises the following steps:
step 1, pressing a ceramic blank meeting the allowance of a set size according to the size of a target part, wherein the shape of the ceramic blank is required to be determined before pressing, the volume required when the ceramic blank forms a minimum cylinder enveloping the target part is set to be a first numerical value, and the volume required when the ceramic blank forms a minimum cuboid enveloping the target part is set to be a second numerical value; and taking the shape corresponding to the smaller one of the first numerical value and the second numerical value to finish the pressing of the ceramic green body.
Step 2, preprocessing a ceramic green body: and if the ceramic green body is a cylinder, processing the ceramic green body into the minimum cylinder step shaft of the envelope target part by adopting a turning mode.
If the ceramic green body is a cuboid, the ceramic green body is processed into a minimum enveloping body structure enveloping the target part by adopting a milling method.
And 3, sintering the preprocessed ceramic green body to obtain the ceramic part.
And 4, finishing the fine reference processing in the ceramic part by adopting a diamond turning tool or a diamond electroplating grinding head.
And 5, roughly machining the complex outer surface of the ceramic part on a milling machine by using an electroplating diamond grinding head.
And 6, performing finish machining on the complex outer surface of the ceramic part by using a diamond grinding head.
Further, the ceramic green body is pressed by adopting a static pressure forming or dry pressing forming method.
Further, the size allowance between the ceramic green body and the target part is larger than the set size allowance.
Further, after the ceramic green body is turned into a minimum cylindrical step shaft, process holes are prefabricated at two ends of the minimum step shaft.
Further, in step 4, if the ceramic green body is a cylinder, performing precision reference machining on the outer circle of the minimum cylindrical step shaft, taking the precisely machined outer circle as a precision reference, and preparing for next external surface milling. If the green body is a cuboid, a diamond electroplating grinding head is used for fine-reference processing.
And further, spraying cooling liquid on the outer surface of the ceramic part during milling by using an electroplating diamond grinding head in the step 5 or milling by using a diamond grinding head in the step 6.
The invention has the beneficial effects that:
according to the shape of the ceramic part to be processed, the ceramic blank is pressed into a cylinder or a cuboid, and the pressed ceramic blank has only the two shapes, so that a mould for fitting the shape and the size of the ceramic part is not required to be designed, and the process and the cost for forming the ceramic blank are greatly reduced.
By adopting the mode of turning or milling before sintering the ceramic green body, under the condition that the ceramic green body can envelop the ceramic part, the material before sintering the ceramic green body is reduced, the material removal amount on the surface of the sintered ceramic part is reduced, and the difficulty in surface processing of the ceramic part is simplified.
The electroplated diamond grinding head is adopted to process the ceramic, so that the processing efficiency is greatly improved, the phenomena of edge breakage, cracking and the like in the processing process are well inhibited, and the surface quality of the processed surface is improved. The processing process does not need a special machine tool, and the processing cost is low, the efficiency is high, and the ceramic parts can be widely applied.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the application and, together with the description, serve to explain the application and are not intended to limit the application.
FIG. 1 is a schematic illustration of a target part in an embodiment of the invention;
FIG. 2 is a schematic view of a ceramic green body in a cylindrical shape after compaction molding in an embodiment of the present invention;
FIG. 3 is a schematic view of a green ceramic body in an embodiment of the present invention, after being formed by compaction, showing a rectangular parallelepiped shape;
FIG. 4 is a schematic diagram of a cylindrical ceramic green body after preprocessing according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a rectangular parallelepiped ceramic green body after preprocessing in an embodiment of the present invention;
FIG. 6 is a schematic view of the clamping of the cylindrical step shaft according to the embodiment of the present invention;
FIG. 7 is a schematic view of clamping a workpiece during preprocessing of a rectangular ceramic green body according to an embodiment of the present invention;
FIG. 8 is a schematic view of a fixture used for curved surface clamping according to an embodiment of the present invention;
fig. 9 is a schematic view of an electroplated diamond grinding head in an embodiment of the present invention.
In the figure: 1. a target part; 2. cylindrical ceramic green bodies; 3. a rectangular ceramic green body; 4. a cylindrical step shaft; 5. a prismoid-shaped workpiece; 6. pressing a plate; 7. a lower clamp; 8. an upper clamp; 9. electroplating the diamond grinding head.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide a preferred description of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
In an exemplary embodiment of the present invention, a method for efficiently manufacturing a large-sized complex-shaped ceramic part is exemplified by a large-sized complex-shaped commercial yttria-stabilized zirconia ceramic part as shown in fig. 1, as shown in fig. 2 to 9, and comprises the following steps:
step 1, mixing materials, pressing and forming: and mixing materials according to the commercial yttria-stabilized zirconia ceramic material required by processing, and performing compression molding. And pressing according to the shape of the target part 1, and selecting a cylindrical ceramic blank 2 or a rectangular ceramic blank 3 in a pressing forming shape according to the principle of minimum allowance. The minimum machining allowance of 20mm is reserved between the ceramic green body formed by pressing and the shape of the target part 1.
Step 2, preprocessing the pressed ceramic green body: the pressed ceramic green body has certain mechanical strength, and can be conveniently machined by using a lathe or a milling machine according to different formed shapes. And (3) machining the cylindrical ceramic blank 2 into a cylindrical step shaft 4 wrapping the target part 1 by using a lathe according to the shape requirement of the final workpiece, wherein the minimum allowance between the cylindrical step shaft 4 and the shape of the target part 1 is larger than 10 mm. Meanwhile, process holes for subsequent turning and positioning are machined at the top end and the bottom end of the cylindrical step shaft 4.
The rectangular ceramic blank 3 is processed into a prismoid workpiece 5 wrapping the target part 1 by using a milling machine according to the requirement of the shape of the final workpiece, and the minimum allowance of the prismoid workpiece 5 and the shape of the target part 1 is larger than 10 mm. Meanwhile, steps are reserved at the top end and the bottom end of the frustum pyramid-shaped workpiece 5 and are used as a reference for subsequent processing.
The processed ceramic green body is subjected to next sintering, the size shrinkage is inevitable along with the densification of the ceramic in the sintering process, and the shrinkage deformation is uncontrollable, so that the processing allowance is necessary to be reserved.
And 3, sintering the ceramic green body: and (4) preprocessing the ceramic blank with enough processing allowance in the previous step, and sintering the ceramic blank according to the sintering requirement of the corresponding ceramic material in the sintering process.
And 4, processing of a fine standard: and (3) performing finish machining on the step shaft at the lowest layer by using a diamond lathe tool to machine a cylindrical shape with the diameter of 20mm to form a finish reference by using the fabrication hole prefabricated in the previous step as a positioning position on the lathe. And (3) after sintering the prismatic table-shaped workpiece 5, performing precision reference processing on the blank workpiece on a milling machine by using an electroplated diamond grinding head 9 of a hard alloy cutter bar.
Step 5, rough machining of the outer surface: and (4) positioning and clamping by using the processed precise reference, roughly processing the shape surface on a milling machine, and reserving 1mm of processing allowance. The processing parameters that can be referred to are: the diamond grinding head 9 with the diameter of the grinding head of 20mm, the height of a plating layer of 10mm, a chamfer angle of R3 and a mesh of 80 is used for processing on a milling machine at the rotating speed of 1600rpm, the cutting depth of 10mm, the cutting width of 10mm and the feeding speed of 400mm/min, and sufficient cooling liquid is used for cooling in the processing process.
Step 6, finish machining of the outer surface: and (5) positioning and clamping by using the machined precise reference, and machining the shape surface on a milling machine. The processing parameters that can be referred to are: the diamond grinding head 9 with the diameter of the grinding head of 20mm, the height of a plating layer of 10mm, a chamfer angle of R3 and a mesh of 80 is used for processing on a milling machine at the rotating speed of 1600rpm, the cutting depth of 10mm, the cutting width of 10mm and the feeding speed of 400mm/min, and sufficient cooling liquid is used for cooling in the processing process. And finishing the shape surface of the middle part. After finishing the surface of the middle portion, the ceramic part is clamped by using the upper jig 8 and the lower jig 7 shown in fig. 8 or the pressing plate 6 shown in fig. 6, and both end surfaces of the ceramic part are machined. In a typical machining case, after the machining parameters are used for continuous machining for 10 hours, the cutter is not obviously abraded, the machining process is stable, and the phenomenon of edge breakage of a workpiece is avoided.
Compared with the traditional method for processing the commercial yttria-stabilized zirconia ceramics by using the diamond blade, the service life of the cutter is obviously prolonged. Compared with turning, the material removal efficiency is improved by 5000 times. In the machining process, the material removing mode is actually grinding machining, the cutting force is much smaller than that of milling, and the damage to a material matrix is smaller. With sufficient lubrication, damage to the machined surface, such as microcracks, surface burns, are significantly reduced. The processed surface has better roughness and no obvious processing texture.
Compared with the traditional method of turning by using a diamond turning tool, the material removal rate of the processing mode provided by the invention is improved by 5000 times, and the processing efficiency is greatly improved.
Although the embodiments of the present invention have been described with reference to the accompanying drawings, it is not intended to limit the scope of the present invention, and it should be understood by those skilled in the art that various modifications and variations can be made without inventive efforts by those skilled in the art based on the technical solution of the present invention.

Claims (7)

1. A method for manufacturing a large-size ceramic part with a complex profile is characterized by comprising the following steps,
step 1, pressing a ceramic blank meeting the allowance of a set size according to the size of a target part, wherein the shape of the ceramic blank is determined before pressing,
setting the volume required when the ceramic green body forms a minimum cylinder enveloping the target part as a first value, and setting the volume required when the ceramic green body forms a minimum cuboid enveloping the target part as a second value; taking the shape corresponding to the smaller one of the first numerical value and the second numerical value to complete the pressing of the ceramic green body;
step 2, preprocessing a ceramic green body: if the ceramic green body is a cylinder, processing the ceramic green body into a minimum cylinder step shaft enveloping the target part in a turning mode;
if the ceramic green body is a cuboid, processing the ceramic green body into a minimum enveloping body structure enveloping the target part by adopting a milling method;
step 3, sintering the preprocessed ceramic green body to obtain a ceramic part;
step 4, finishing the fine reference processing in the ceramic part by adopting a diamond turning tool or a diamond electroplating grinding head;
step 5, roughly machining the complex outer surface of the ceramic part on a milling machine by using an electroplating diamond grinding head;
and 6, performing finish machining on the complex outer surface of the ceramic part by using a diamond grinding head.
2. The method for manufacturing large-size complex-shaped ceramic parts according to claim 1, wherein in the step 1, the ceramic green body is pressed by a static pressure forming method or a dry pressing method.
3. The method for manufacturing a large-sized complex-shaped ceramic part according to claim 2, wherein in the step 1, the size margin between the ceramic green body and the target part is larger than the set size margin.
4. The method for manufacturing a large-sized complex-shaped ceramic part according to claim 1, wherein in the step 2, if the ceramic green body is a cylinder, after turning the ceramic green body into a minimum cylindrical step shaft, fabrication holes are preformed at two ends of the minimum step shaft.
5. The method for manufacturing a large-sized ceramic part with a complex surface according to claim 1, wherein in the step 4, if the ceramic blank is a cylinder, the outer circle of the smallest cylindrical step shaft is processed by a fine reference, and the finished outer circle is used as a fine reference to prepare for the next milling of the external surface.
6. The method for manufacturing large-sized complex-shaped ceramic parts according to claim 1, wherein in the step 4, if the green body is a rectangular parallelepiped, the fine reference machining is performed by using a diamond electroplating grinding head.
7. The manufacturing method of large-sized complex-shaped surface ceramic parts according to claim 1, wherein a cooling liquid is sprayed to the outer surface of the ceramic part when an electroplating diamond grinding head or a diamond grinding head is used for milling.
CN202010019246.9A 2020-01-08 2020-01-08 Manufacturing method of large-size ceramic part with complex surface Pending CN111098392A (en)

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CN113601732A (en) * 2021-06-26 2021-11-05 成都凯迪精工科技有限责任公司 Processing method of ceramic material wind tunnel model
CN114290263A (en) * 2021-12-29 2022-04-08 广东东唯新材料有限公司 Manufacturing method of curved surface supporting base of ceramic plate and curved surface supporting base

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CN113601732A (en) * 2021-06-26 2021-11-05 成都凯迪精工科技有限责任公司 Processing method of ceramic material wind tunnel model
CN113601732B (en) * 2021-06-26 2023-11-03 成都凯迪精工科技有限责任公司 Processing method of ceramic material wind tunnel model
CN114290263A (en) * 2021-12-29 2022-04-08 广东东唯新材料有限公司 Manufacturing method of curved surface supporting base of ceramic plate and curved surface supporting base

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Application publication date: 20200505