CN115383631A - 一种提高氧化铝基陶瓷刀具表面性能的处理方法 - Google Patents
一种提高氧化铝基陶瓷刀具表面性能的处理方法 Download PDFInfo
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Abstract
一种提高氧化铝基陶瓷刀具表面性能的处理方法，包括下述工艺步骤：首先选择氧化铝基陶瓷刀具，采用丙酮溶液进行超声波清洗30min去除刀具表面油污等杂质；然后将处理后的刀具放于自动液体喷砂机中，并保证待处理刀具位于夹具中心，喷砂装置的磨料为ZrO2或Al2O3颗粒，并由高压气体推动磨料和水的混合物冲击刀具表面；最后将处理后的刀具进行丙酮溶液的超声波清洗10min，去除表面残留的磨料颗粒等杂质，即得。使用微喷砂处理工艺对氧化铝基陶瓷刀具进行表面处理，可以提高表面维氏硬度、断裂韧度以及残余压应力，抑制或消除表面微裂纹，提高刀具寿命。
Description
技术领域
本发明涉及一种提高氧化铝基陶瓷刀具表面性能的处理方法，属于表面处理领域。
背景技术
随着制造业的飞速发展，新型材料不断涌现，对刀具提出更高的要求，氧化铝基陶瓷刀具以高硬度、高耐磨性、耐高温性、化学稳定性好、不易与金属发生粘结、摩擦系数低等优点得到广泛应用，成为机械加工行业的重要组成部分，其中日本对陶瓷刀具的使用占总刀具的70%以上。但氧化铝基陶瓷刀具在高速干车削高温合金等难加工材料时，容易出现磨损严重、寿命较低等现象。因此研究如何降低刀具磨损、提高陶瓷刀具寿命迫在眉睫。
微喷砂处理技术具有操作简单、灵活、加工效率高、磨料利用率高等特点，是从磨料水射流加工发展起来的一种表面改性处理技术，适合对一些尺寸小的工件或刀具表面进行处理，可以改变原表面力学性能和几何特性。氧化铝基陶瓷刀具表面力学性能包括：维氏硬度、断裂韧度、残余应力等。通过对氧化铝基陶瓷刀具进行微喷砂处理，可以提高刀具表面维氏硬度、断裂韧度以及残余压应力，最终降低刀具磨损，延长刀具切削寿命。
发明内容
本发明的目的，是提供一种提高氧化铝基陶瓷刀具表面性能的处理方法，能有效改善刀具的表面完整性与切削性能。其技术方案为：
一种提高氧化铝基陶瓷刀具表面性能的处理方法，包括如下步骤：
1）选择氧化铝基陶瓷刀具，并采用丙酮溶液进行超声波清洗去除表面油污等杂质；
2）清洗后的刀具放入自动液体喷砂机中，并确保待处理刀具位于夹具中心，喷砂装置的磨料为ZrO2或Al2O3颗粒，并由高压气体推动磨料和水的混合物冲击刀具表面；
3）将处理后的刀具再次使用丙酮溶液进行超声波清洗，去除表面残留的磨料颗粒；
4）检测处理后的刀具表面微观形貌、维氏硬度、断裂韧度以及残余应力；
5）对处理后的刀具进行切削试验，测试在进行金属加工时寿命提升程度，相比未处理刀具，处理后的氧化铝基陶瓷刀具切削力降低，刀具寿命明显提升。
进一步地，步骤1）超声波清洗30min。
进一步地，步骤2）所述的微喷砂处理，颗粒粒度直径低于30μm，按照水料比5:1配置喷砂溶液，喷砂角度90°，喷砂距离100mm，喷砂时间1~6min，喷砂压强0.3~0.4MPa。
进一步地，步骤3）超声波清洗10min。
进一步地，步骤5）切削速度v=100-300m/min，切削深度a p =0.1-0.2mm，进给量f=0.1mm/r。
本发明具有以下有益效果：
本发明为成品氧化铝基陶瓷刀具厂家提供一种表面处理工艺，能够解决因刀具磨损严重导致的刀具寿命较低的问题。微喷砂处理可以改变原表面力学性能和几何特性，提高刀具表面维氏硬度、断裂韧度以及残余压应力，抑制或消除刀具表面微裂纹，最终降低刀具磨损，延长刀具切削寿命。
具体实施方式
实施例：
一种提高氧化铝基陶瓷刀具表面力学性能的处理方法，包括下述工艺步骤：
Al2O3-SiCw陶瓷刀具（瑞典SANDVIK），9080-2W-ZSK自动液体喷砂机，QUANTA FEG250型电子扫描显微镜（SEM）观察表面微观形貌，WYKO NT9300光学轮廓仪测量表面粗糙度，X射线衍射应力仪Stresstech Xstress 3000 G2R测量表面残余应力，工件材料为航空航天发动机叶轮叶片常用材料钴基高温合金GH605，在数控车床CKD6136i（大连机床厂）上进行试验，选用USB200数码工具显微镜检测刀具磨损。
1）氧化铝基陶瓷刀具选用瑞典SANDVIK的Al2O3-SiCw陶瓷刀具，采用丙酮溶液超声波清洗30min，去除表面油污，备用；
2）将超声波清洗后的Al2O3-SiCw陶瓷刀具放于自动液体喷砂机中，并保证待处理刀具位于夹具中心。喷砂磨料为ZrO2颗粒，磨料粒径为26μm，并由高压气体带动磨料和水的混合物。水与磨料配比为5∶1，喷砂角度90°，喷砂距离100mm，喷砂时间4min，喷砂压强0.4MPa；
3）将步骤2）处理后的Al2O3-SiCw陶瓷刀具采用丙酮溶液进行超声波清洗10min，目的去除表面残留磨料颗粒；
4）检测处理后的刀具表面性能，发现微喷砂处理后的刀具表面维氏硬度提高16%，断裂韧度提高15%，残余压应力提高50%；
5）选取切削速度v=100-300m/min，切削深度a p =0.1-0.2mm，进给量f=0.1mm/r进行干切削。在保证加工效率前提下，以刀具寿命为判断标准，选取最佳切削参数；
6）采用切削速度v=250m/min，切削深度a p =0.2mm，进给量f=0.1mm/r进行高速干车削，以VB=0.3mm为刀具失效标准；
7)将微喷砂处理的Al2O3-SiCw陶瓷刀具进行了高速干切削钴基高温合金GH605试验，相比未处理刀具寿命提高20%。
Claims (5)
1.一种提高氧化铝基陶瓷刀具表面性能的处理方法，其特征包括下述工艺步骤：
1）选择氧化铝基陶瓷刀具，并采用丙酮溶液进行超声波清洗去除表面油污等杂质；
2）清洗后的刀具放入自动液体喷砂机中，并确保待处理刀具位于夹具中心，喷砂装置的磨料为ZrO2或Al2O3颗粒，并由高压气体推动磨料和水的混合物冲击刀具表面；
3）将处理后的刀具再次使用丙酮溶液进行超声波清洗，去除表面残留的磨料颗粒；
4）检测处理后的刀具表面微观形貌、维氏硬度、断裂韧度以及残余应力；
5）对处理后的刀具进行切削试验，测试在进行金属加工时寿命提升程度，相比未处理刀具，处理后的氧化铝基陶瓷刀具切削力降低，刀具寿命明显提升。
2.根据权利要求1所述的提高氧化铝基陶瓷刀具表面性能的处理方法，其特征在于：步骤1）超声波清洗30min。
3.根据权利要求1所述的提高氧化铝基陶瓷刀具表面性能的处理方法，其特征在于：步骤2）所述的微喷砂处理，颗粒粒度直径要低于30μm，按照水料比5:1配置喷砂溶液，喷砂角度90°，喷砂距离100mm，喷砂时间1~6min，喷砂压强0.3~0.4MPa。
4.根据权利要求1所述的提高氧化铝基陶瓷刀具表面性能的处理方法，其特征在于：步骤3）超声波清洗10min。
5.根据权利要求1所述的提高氧化铝基陶瓷刀具表面性能的处理方法，其特征在于：步骤5）切削速度v=100-300m/min，a p =0.1-0.2mm，f=0.1mm/r。
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| Publication number | Priority date | Publication date | Assignee | Title |
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| KR101432730B1 (ko) * | 2013-02-20 | 2014-08-22 | 인하대학교 산학협력단 | 절삭공구의 표면 연마를 위한 연마재, 및 이를 이용하는 절삭공구 표면 연마방법 |
| CN111660208A (zh) * | 2020-06-03 | 2020-09-15 | 山东理工大学 | 一种提高金属加工工具寿命的复合表面处理方法 |
| CN111665159A (zh) * | 2020-06-03 | 2020-09-15 | 山东理工大学 | 一种延长金属切削涂层刀具寿命的方法 |
| CN111660145A (zh) * | 2020-06-03 | 2020-09-15 | 山东理工大学 | 一种降低金属加工成本的工具处理方法 |
| CN111687438A (zh) * | 2020-06-03 | 2020-09-22 | 山东理工大学 | 一种降低断续切削成本的涂层刀具处理方法 |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101432730B1 (ko) * | 2013-02-20 | 2014-08-22 | 인하대학교 산학협력단 | 절삭공구의 표면 연마를 위한 연마재, 및 이를 이용하는 절삭공구 표면 연마방법 |
| CN111660208A (zh) * | 2020-06-03 | 2020-09-15 | 山东理工大学 | 一种提高金属加工工具寿命的复合表面处理方法 |
| CN111665159A (zh) * | 2020-06-03 | 2020-09-15 | 山东理工大学 | 一种延长金属切削涂层刀具寿命的方法 |
| CN111660145A (zh) * | 2020-06-03 | 2020-09-15 | 山东理工大学 | 一种降低金属加工成本的工具处理方法 |
| CN111687438A (zh) * | 2020-06-03 | 2020-09-22 | 山东理工大学 | 一种降低断续切削成本的涂层刀具处理方法 |
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