Performance and wear mechanisms of novel superhard diamond and boron nitride based tools in machining Al-SiCp metal matrix composite . Performance and wear mechanisms of novel superhard diamond and boron nitride based tools in machining Al-SiCp metal matrix composite. Wear,[376][377][152][153][154][155][156][157][158][159][160][161][162][163][164]. https://doi.
AbstractMetal matrix composites are the desired materials in aerospace and automotive industries since they possess high specific strength. However addition of reinforcement to the matrix material brings the adverse effects of high wear rate of tool materials used in their machining. The current study addresses the issues of wear and performance of superhard tools when high speed machining cast Al-Si alloy reinforced with particulate SiC (20% vol.). A wide range of developed superhard materials was compared to the commercial PCD tools. Nano grain sized wBN-cBN, binderless cBN; B6O-cBN, nano-diamond with WC binder; diamond/MAX-phase; and diamond/SiC tool materials were employed. Tool wear tests involved dry machining at cutting speeds 200 and 400 m/min at fixed cutting length of 14 000 meters. Use of nano-diamond/WC and diamond/MAXphase composites resulted in their rapid deterioration due to primarily adhesive pluck-out of diamond and binder phase. Diamond/SiC material exhibited slightly lower performance than the PCD, with the primary wear being the abrasive on the SiC binder phase. Machining with cBN-based tooling at lower speed lead to formation of stable build-up layer, frequently accompanied by severe seizure of tool and workpiece material. However at speed of 400 m/min the absence of such build-up layer caused rapid tool wear. In case of PCD and diamond-SiC tooling build-up layer remained stable in the whole cutting speed range. Presence of chemical and diffusional wear mechanisms for this tooling has been confirmed through scanning and transmission electron microscopy. Archard-type model of abrasive tool wear was developed for modelling of tool deterioration for all studied tool materials.
The work reported on here involved the development of several samples of "diamond-SiC" composite produced under sintering pressures of up to 9.0 GPa at temperatures of up to 1973 7K. The average size of the diamond micropowder crystals used was 40/28 µm. The sintering process was carried out in a 2500-ton hydraulic press equipped with an anvil-type high-pressure device having a toroidal work surface and a central concavity diameter of 20 mm. The microhardness and wear resistance of the samples were found to be dependent on the sintering pressure. The experimental results indicated that the maximum microhardness and minimum wear resistance coefficients of each compact were attained when the pressure applied during sintering exceeded 6.5 GPa. Based on the established values of pressure, this study served to identify the types of devices applicable for the manufacture of composite material inserts for a variety of rock drilling applications
ResumoOs micropós de diamante de granulometria 40/28 µm foram sinterizados nas condições de alta pressão, de 6,0 a 8,0 GPa, e temperaturas de 1600 ºC a 1800 ºC. Com o objetivo da obtenção de policristais compactos de resistência mecânica determinada. Os experimentos foram realizados nos dispositivos de alta pressão do tipo bigorna com concavidade toroidal, em tempos variáveis de até 80 s. Foram obtidos compactos com diâmetro de 4,5 mm e altura de 5,0 mm. Foram determinadas as dependências entre a densidade dos policristais e tempo de duração do processo de sinterização sob três temperaturas. Estudou-se a cinética de grafitização dos grãos dos compactos sob a ação das altas pressões e temperaturas. Foi concluído que além de mecanismos de consolidação já estabelecidos, atua também o mecanismo de cisalhamento parcial. Palavras-chave: diamante policristalino, altas pressões, sinterização, mecanismos de consolidação.
Abstract
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