CN111318860A - Method and device for processing ceramic particle reinforced metal matrix composite - Google Patents
Method and device for processing ceramic particle reinforced metal matrix composite Download PDFInfo
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- CN111318860A CN111318860A CN202010229727.2A CN202010229727A CN111318860A CN 111318860 A CN111318860 A CN 111318860A CN 202010229727 A CN202010229727 A CN 202010229727A CN 111318860 A CN111318860 A CN 111318860A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/06—Surface hardening
- C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D11/00—Process control or regulation for heat treatments
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
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Abstract
The invention belongs to the field of composite material processing, and particularly discloses a processing method and a device for a ceramic particle reinforced metal matrix composite material, which comprises the following steps: s1 laser heating surface melting modification: carrying out laser heating scanning treatment on the surface of the ceramic particle reinforced metal matrix composite material so as to form a layer of laser modified area without/with few ceramic reinforced particles on the surface of the ceramic particle reinforced metal matrix composite material; s2 ultra-precision machining: and milling the laser modified area by using a milling cutter, finishing the laser modified area by using a fly cutter, wherein the total cutting amount of the milling cutter and the fly cutter to the laser modified area is not more than the depth of the laser modified area, and finishing the processing of the ceramic particle reinforced metal matrix composite. The invention can obviously improve the problems of cutter excessive wear and poor surface integrity in the processing of the ceramic particle reinforced metal matrix composite material, and can realize the ultra-precision processing of submicron surface roughness and form and position precision of the material.
Description
Technical Field
The invention belongs to the field of composite material processing, and particularly relates to a processing method and device for a ceramic particle reinforced metal matrix composite material.
Background
Compared with the traditional alloy material, the ceramic particle reinforced metal matrix composite material has the advantages of light weight, high strength, rigidity, hardness and wear resistance, good thermal expansion coefficient, size stability and the like. In recent years, with the rapid development of mechanical manufacturing and material science, the industrial fields of aerospace, military, energy, automobile, electronics, medical treatment, optics and the like have more and more requirements on the material performance and service performance of parts, and the ceramic particle reinforced metal matrix composite material shows good potential in the application of the fields due to the excellent performance. Such materials are typically formed by near net shape forming techniques such as powder metallurgy, hot extrusion, pressure infiltration and casting, and subsequently require mechanical post-processing (e.g., turning, milling, grinding and polishing) to achieve the desired dimensional accuracy and surface quality.
Because of the high amount of high hardness ceramic reinforcing particles in the metal matrix, such composites suffer from severe tool wear and undesirable surface quality during machining, making them typically difficult to machine materials. On the one hand, even diamond tools with very high hardness and good thermal conductivity suffer from the negative problems of excessive wear and premature failure due to the high abrasiveness of the ceramic reinforcing particles and the high adhesion of the metal matrix, which means that the cutting tools need to be replaced from time to time during machining, resulting in increased production time and costs; on the other hand, in the process of interaction between the reinforcing particles and the cutter in the machining process, the reinforcing particles can generate phenomena of crushing, peeling, debonding from a metal matrix and the like, which can leave defects such as holes, cracks, grooves and the like on the machined surface, and simultaneously can cause damage to the subsurface layer of the workpiece to a certain extent under the combined action of the matrix and the reinforcing particles, and the defects and the like can finally cause the reduction of the size precision and the poor surface quality of the workpiece of the material, so that the ultraprecise machining of the material is difficult to realize, and the service performance of the material is seriously influenced.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides a processing method and a processing device for a ceramic particle reinforced metal matrix composite, and aims to remarkably improve the problems of excessive cutter abrasion and poor surface integrity in the processing of the ceramic particle reinforced metal matrix composite by combining a laser heating surface melting modification technology and an ultra-precision processing technology, and realize the ultra-precision processing of the submicron surface roughness and form and position precision of the material.
To achieve the above object, according to one aspect of the present invention, there is provided a method for processing a ceramic particle reinforced metal matrix composite, comprising the steps of:
s1 laser heating surface melting modification: carrying out laser heating scanning treatment on the surface of the ceramic particle reinforced metal matrix composite material so as to form a layer of laser modified area without/with few ceramic reinforced particles on the surface of the ceramic particle reinforced metal matrix composite material;
s2 ultra-precision machining: and milling the laser modified area by using a milling cutter, finishing the laser modified area by using a fly cutter, wherein the total cutting amount of the milling cutter and the fly cutter to the laser modified area is not more than the depth of the laser modified area, and finishing the processing of the ceramic particle reinforced metal matrix composite.
Preferably, before machining, a laser heating temperature field model is established, distribution of a temperature field during machining is simulated and simulated by inputting thermophysical parameters of the ceramic particle reinforced metal matrix composite and laser heating scanning processing parameters, the width and the depth of a laser modification area are predicted, and then parameters of laser heating scanning processing and subsequent ultra-precision machining parameters are determined according to the distribution.
Further preferably, the laser model in the laser heating temperature field model is a gaussian heat source model.
As a further preferred, the thermophysical parameters of the ceramic particle reinforced metal matrix composite include thermal conductivity and specific heat capacity, wherein:
(1) the heat conductivity coefficient is calculated by the following formula:
wherein, Kc，KmAnd KpRespectively the thermal conductivity coefficients of the ceramic particle reinforced metal matrix composite material, the metal matrix material and the reinforced particle material, d is the diameter of the reinforced particle, VpTo enhance the volume fraction of the particles, RBdIs the interfacial thermal resistance of the composite material;
(2) the specific heat capacity is calculated by the following formula:
wherein, Cc，CmAnd CpSpecific heat capacity, rho, of the ceramic particle reinforced metal matrix composite, the metal matrix material and the reinforced particle material, respectivelypAnd ρmDensity, V, of the metal matrix material and of the reinforcing particulate material, respectivelypTo enhance the volume fraction of the particles.
Preferably, during simulation and simulation of the distribution of the temperature field during processing, when the distribution of the temperature field is stable, two paths passing through the center of the laser light source and along the surface and depth directions are established, a temperature-position relation curve is obtained, and the width and depth of the laser modification region are predicted according to the relation between the temperature-position relation curve and the melting point of the metal matrix material.
Further preferably, the parameters of the laser heating scanning process include laser light source power, defocus amount, laser moving speed, and scanning pitch.
According to another aspect of the present invention, there is provided a ceramic particle reinforced metal matrix composite processing apparatus including a headstock, a laser, a spindle, a fly cutter assembly, a milling cutter, and a table, wherein:
the laser and the spindle are both arranged on the spindle box, the workbench is positioned below the laser and the spindle, and a fixed base is arranged on the workbench and used for fixing a material to be processed; the milling cutter is installed at the lower end of the main shaft and used for milling and roughly machining materials to be machined, and the milling cutter is replaced by a fly cutter assembly after rough machining is completed so as to further perform fly cutter finishing machining after milling.
As a further preferred option, the flyer assembly includes a flyer disc, a flyer and a counterweight, wherein the flyer disc is mounted at the lower end of the main shaft, and the flyer and the counterweight are symmetrically mounted on the flyer disc.
Preferably, the fly cutter is a single point diamond fly cutter.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. according to the invention, the ceramic particle reinforced metal matrix composite is treated by adopting a laser heating surface melting modification technology, so that a modified area with few or no ceramic reinforced particles is formed on the surface of the ceramic particle reinforced metal matrix composite, the interaction between a cutter and the reinforced particles can be effectively reduced in the processing process, and compared with the processing of the unmodified composite, the severe abrasion of the cutter can be effectively improved and the service life of the cutter can be prolonged;
2. according to the invention, a modified area with few/no ceramic reinforced particles can be formed by processing the ceramic particle reinforced metal matrix composite material by adopting a laser heating surface melting modification technology, surface defects such as surface holes and cracks formed by failure of the reinforced particles can be effectively avoided in the processing process, compared with the processing of an unmodified metal matrix composite material, the surface quality is obviously improved, and the ultra-precision processing of the submicron surface roughness and form and position precision of the material can be realized;
3. the laser heating temperature field model established by the invention can effectively predict the width and the depth of a material modification area of the laser heating surface modification, can be used for optimizing selection of laser processing parameters and subsequent machining process parameters, and has higher efficiency compared with a method for observing the shape of a workpiece cross section modification area by adopting an experiment.
Drawings
FIG. 1 is a schematic view of a process for manufacturing a ceramic particle reinforced metal matrix composite according to an embodiment of the present invention;
FIG. 2 is a sectional view taken along line A-A of the material of FIG. 1, which is a schematic cross-sectional view of the material after modification;
FIG. 3 is a schematic structural diagram of a processing apparatus for ceramic particle reinforced metal matrix composites according to an embodiment of the present invention;
FIG. 4 is a comparison of an actual molten pool and a simulated molten pool after laser heating surface modification in accordance with an embodiment of the present invention;
FIG. 5 is a schematic diagram of a method for acquiring depth and width of a molten pool by a laser heating temperature field model according to an embodiment of the invention;
FIG. 6 is an optical microscope image of a cross-section of a modified region of a laser heated surface modified material in accordance with an embodiment of the invention;
FIGS. 7a and 7b are graphs comparing tool wear when machining laser modified regions versus unmodified regions in accordance with embodiments of the present invention;
FIGS. 8a and 8b are SEM images of surface quality of laser modified and unmodified areas processed according to an embodiment of the present invention;
fig. 9a and 9b are surface quality white light interference contrast graphs of laser modified and unmodified areas processed according to embodiments of the present invention.
The same reference numbers will be used throughout the drawings to refer to the same or like elements or structures, wherein: 1-a spindle box, 2-a laser, 3-a balancing weight, 4-a material to be processed, 5-a workbench, 6-a fixed base, 7-a fly cutter, 8-a fly cutter disc and 9-a spindle.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
The embodiment of the invention provides a processing method of a ceramic particle reinforced metal matrix composite, which comprises the following steps:
s1 laser heating surface melting modification: carrying out laser heating scanning treatment on the surface of the ceramic particle reinforced metal matrix composite by adopting a high-power laser, and forming a laser modified area without/with few ceramic reinforced particles on the surface of the ceramic particle reinforced metal matrix composite by utilizing the sedimentation and decomposition phenomena of the ceramic reinforced particles in a liquid metal matrix;
s2 ultra-precision machining: and milling the laser modified area by using a milling cutter, namely rough machining, then finishing the laser modified area by using a fly cutter, namely finish machining, wherein the total cutting amount of the milling cutter and the fly cutter to the laser modified area is not more than the depth of the laser modified area, so that the processing of the ceramic particle reinforced metal matrix composite is completed.
Further, before processing, according to a laser heating temperature field simulation technology, a laser heating temperature field model is established by adopting a finite element software laser heat source subprogram, the distribution of the temperature field during processing is simulated and simulated by inputting thermal physical parameters of the ceramic particle reinforced metal matrix composite material and laser heating scanning processing parameters, the width and the depth of a laser modification area are predicted, and then the parameters of laser heating scanning processing and subsequent ultra-precision processing parameters are determined according to the width and the depth of the laser modification area; specifically, the parameters of the laser heating scanning process include laser light source power, defocus amount, laser moving speed, and scanning pitch.
Further, the thermophysical parameters of the ceramic particle reinforced metal matrix composite include a thermal conductivity and a specific heat capacity, wherein:
the heat conductivity coefficient is calculated by the formula (1):
wherein, Kc，KmAnd KpRespectively the thermal conductivity coefficients of the ceramic particle reinforced metal matrix composite material, the metal matrix material and the reinforced particle material, d is the diameter of the reinforced particle, VpTo enhance the volume fraction of the particles, RBdIs the interfacial thermal resistance of the composite material;
the specific heat capacity is calculated by the formula (2):
wherein, Cc，CmAnd CpSpecific heat capacity, rho, of the ceramic particle reinforced metal matrix composite, the metal matrix material and the reinforced particle material, respectivelypAnd ρmDensity, V, of the metal matrix material and of the reinforcing particulate material, respectivelypTo enhance the volume fraction of the particles.
Furthermore, when the distribution of the temperature field is simulated and simulated during processing, two paths which pass through the center of the laser light source and are along the surface and depth directions are established when the distribution of the temperature field is stable, a relation curve of the temperature and the position is obtained, and the width and the depth of the laser modification area are predicted according to the relation between the relation curve and the melting point of the metal matrix material.
A ceramic particle reinforced metal matrix composite processing apparatus for implementing the above method, as shown in fig. 3, comprises a headstock 1, a laser 2, a spindle 9, a fly cutter assembly, a milling cutter, and a table 5, wherein:
the laser 2 and the spindle 9 are both arranged on the spindle box 1, the workbench 5 is arranged on a machine tool frame, is positioned below the laser 2 and the spindle 9, and is provided with a fixed base 6, and the fixed base 6 is used for fixing a material 4 to be processed; the milling cutter is arranged at the lower end of the main shaft 9 and used for milling and roughly machining the material 4 to be machined, and the milling cutter is replaced by a fly cutter assembly after rough machining is finished so as to further perform fly cutter finishing machining after milling;
specifically, the flying cutter subassembly includes flying cutter dish 8, flying cutter 7 and balancing weight 3, wherein, flying cutter dish 8 is installed the lower extreme of main shaft 9, flying cutter 7 with balancing weight 3 installs symmetrically on flying cutter dish 8, preferably, flying cutter 7 is single-point diamond flying cutter.
The following are specific examples:
selecting a SiCp/Al composite material with the volume fraction of 40% and the reinforced particle average size of 10 microns; firstly, establishing a geometric model of a workpiece in ABAQUS finite element simulation software, and carrying out grid division by adopting a DC3D8 unit, wherein parameters such as material density, heat conduction coefficient, specific heat capacity and the like need to be input into the model;
thermophysical parameters of the 40 vol% SiCp/Al composite were calculated according to equations (1) and (2) and the results are shown in Table 1:
TABLE 1
The heat source is an IPG YLR-4000 optical fiber laser with the wavelength of 1070nm, and the laser model adopts a Gaussian heat source model q (x, y) which is expressed by the formula (3):
wherein r is0The effective radius of the laser heat source is shown, r is the distance between a point with coordinates (x, y) and the center position of the light source, P is the laser power, and lambda is the absorptivity of the material to the laser energy.
The absorption rate lambda of the 40 vol% SiCp/Al composite material to laser is 0.226 through experimental calibration, and as shown in fig. 1 and fig. 2, the laser surface modification of the material is carried out by controlling parameters such as laser source power, defocusing amount (spot size), moving speed and the like; the simulation of the laser temperature field is realized through the DFLUX subprogram, when the laser heating is in a stable state, as shown in figure 4, a group of corresponding experimental groups and simulation groups are selected for comparison and verification (the laser temperature field is 2000W, the defocusing amount is 10mm, and the moving speed is 50mm/s), and the proposed laser heating temperature field model has a good prediction effect; as shown in fig. 5, a cross section B-B is taken from the center of the over-laser light source, two paths, Path1 and Path2, are established, a temperature-position relationship curve is obtained and is introduced into MATLAB, and the intersection point of the curve and the 660 ℃ solid-liquid boundary of the aluminum matrix material is calculated to predict the width and depth of the molten pool, so as to optimize the laser heating process parameters and guide the selection of the subsequent machining process parameters.
Through analysis of different sets of simulation results, the laser power P is preferably 2000W, the laser moving speed V is 50mm/s, and the radius r of the light source is preferably selected0The size and the shape of the modified area are proper when the laser defocusing amount is 1mm and the scanning distance is 0.5mm, as shown in fig. 6; because the laser heating temperature reaches the melting point of the aluminum matrix but not the melting point of the SiC reinforced particles, and the density of the SiC particles is higher than that of the aluminum matrix, the SiC particles sink in a liquid aluminum molten pool and are gathered at the bottom of the molten pool, and in addition, the SiC particles and the liquid aluminum react chemically under certain temperature conditions to generate new substances (such as Al)4SiC4And Si, etc.), the hardness and amount of the new generated substances are much smaller than those of SiC before modification, finally a modified region with few/no SiC reinforced particles is formed on the surface of the material, and the processability of the modified region is obviously improved compared with that of the modified region before non-modification.
Then, a PCD milling cutter with mixed grain sizes of 30 microns and 2 microns is installed at the lower end of the main shaft, laser modified and unmodified areas are machined, machining parameters are that the rotation speed of the main shaft is 20000rpm, the cutting depth is 50 microns, the feed rate is 200mm/min, the cutting distance is 300mm, the average wear width of the flank face of the cutter is observed by using an SEM, as shown in figures 7a and 7b, the average wear width of the flank face of the cutter for machining the unmodified area is 42.39 microns, the average wear width of the flank face of the cutter for machining the modified area is 16.78 microns, and the average wear width of the flank face is reduced by 60.42%.
Then installing a fly cutter system at the lower end of the main shaft, adopting a single-point diamond fly cutter to perform finishing processing on laser modified and unmodified areas, wherein the processing parameters are that the rotating speed of the main shaft is 3000rpm, the axial cutting depth is 10 mu m, the feeding amount is 6mm/min, performing SEM observation on the surface quality after processing, and the results are shown in figures 8a and 8 b; as shown in fig. 9a and 9b, the surface quality of the laser-modified and unmodified regions after fly-cutting was measured by a white light interferometer, and Sa (arithmetic mean height of the entire surface) was used as a measurement standard, and the surface quality Sa of the unmodified region after fly-cutting was 0.328 μm, the surface quality Sa of the modified region was 0.047 μm, and the surface quality after laser modification was improved by almost 7 times, demonstrating that the present invention can realize ultra-precision processing of submicron-level surface roughness and form and position accuracy of the SiCp/Al composite material.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (9)
1. A processing method of a ceramic particle reinforced metal matrix composite is characterized by comprising the following steps:
s1 laser heating surface melting modification: carrying out laser heating scanning treatment on the surface of the ceramic particle reinforced metal matrix composite material so as to form a layer of laser modified area without/with few ceramic reinforced particles on the surface of the ceramic particle reinforced metal matrix composite material;
s2 ultra-precision machining: and milling the laser modified area by using a milling cutter, finishing the laser modified area by using a fly cutter, wherein the total cutting amount of the milling cutter and the fly cutter to the laser modified area is not more than the depth of the laser modified area, and finishing the processing of the ceramic particle reinforced metal matrix composite.
2. The method of processing a ceramic particle reinforced metal matrix composite material according to claim 1, wherein before processing, a laser heating temperature field model is established, the distribution of the temperature field during processing is simulated and simulated by inputting the thermophysical parameters of the ceramic particle reinforced metal matrix composite material and the laser heating scanning processing parameters, and the width and depth of the laser modification region are predicted, so as to determine the parameters of the laser heating scanning processing and the subsequent ultra-precision processing parameters.
3. The method of claim 2, wherein the laser pattern of the laser heating temperature field pattern is a gaussian heat source pattern.
4. The method of processing a ceramic particle reinforced metal matrix composite as recited in claim 2, wherein the thermophysical parameters of the ceramic particle reinforced metal matrix composite include a thermal conductivity and a specific heat capacity, wherein:
(1) the heat conductivity coefficient is calculated by the following formula:
wherein, Kc，KmAnd KpRespectively the thermal conductivity coefficients of the ceramic particle reinforced metal matrix composite material, the metal matrix material and the reinforced particle material, d is the diameter of the reinforced particle, VpTo enhance the volume fraction of the particles, RBdIs the interfacial thermal resistance of the composite material;
(2) the specific heat capacity is calculated by the following formula:
wherein, Cc，CmAnd CpSpecific heat capacity, rho, of the ceramic particle reinforced metal matrix composite, the metal matrix material and the reinforced particle material, respectivelypAnd ρmDensity, V, of the metal matrix material and of the reinforcing particulate material, respectivelypTo enhance the volume fraction of the particles.
5. The method of claim 2, wherein during simulation and simulation of the temperature field distribution during the processing, two paths are established through the center of the laser source and along the surface and depth directions when the temperature field distribution is stabilized, and the temperature-position relationship curve is obtained, and the width and depth of the laser modification region are predicted from the relationship between the temperature-position relationship curve and the melting point of the metal matrix material.
6. The method of processing a ceramic particle reinforced metal matrix composite material as recited in claim 2, wherein the parameters of the laser heating scanning process include laser source power, defocus amount, laser moving speed, and scanning pitch.
7. A ceramic particle reinforced metal matrix composite processing apparatus for carrying out the method according to any one of claims 1 to 6, comprising a headstock (1), a laser (2), a spindle (9), a fly-cutter assembly, a milling cutter and a table (5), wherein:
the laser (2) and the spindle (9) are both arranged on the spindle box (1), the workbench (5) is positioned below the laser (2) and the spindle (9), and is provided with a fixed base (6), and the fixed base (6) is used for fixing a material (4) to be processed; the milling cutter is installed at the lower end of the main shaft (9) and used for milling and roughly machining a material (4) to be machined, and the milling cutter is replaced by a fly cutter assembly after rough machining is completed so as to further perform fly cutter finishing machining after milling.
8. The ceramic particle reinforced metal matrix composite processing device according to claim 7, wherein the flyer assembly comprises a flyer disk (8), a flyer (7) and a counterweight (3), wherein the flyer disk (8) is mounted at the lower end of the main shaft (9), and the flyer (7) and the counterweight (3) are symmetrically mounted on the flyer disk (8).
9. The ceramic particle reinforced metal matrix composite processing device according to claim 8, wherein the fly cutter (7) is a single point diamond fly cutter.
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| CN113758419A (en) * | 2021-09-08 | 2021-12-07 | 芜湖承启模具工业有限公司 | Laser calibration die machining system and method |
| CN113758419B (en) * | 2021-09-08 | 2024-05-10 | 芜湖承启工业有限公司 | Laser calibration mold processing system and method |
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