Who is the main tool for ceramic tools and super-hard materials?

Tool material development background:

The development history of tool materials is the history of metal cutting processing development and innovation. The development of tool materials is changing with each passing day, and the cutting process is continuously improved to a new level. Today's ceramic tools and super-hard tool materials have more than 100 times faster cutting speed than previous carbon tool steels. It can be seen that in order to meet the needs of the development of new industries, people's innovation ability is constantly being explored, and tool materials are also adapting to this survival of the fittest. The environment, the emergence of each new tool material, has made the ability and level of machining further.

For more than 130 years, tool materials have grown from carbon tool steel to superhard tool materials. In the 18th century, carbon tool steel first appeared, with a cutting temperature of 200~250 °C, and the cutting speed was only 4~10m/min. In 1990, high-speed steel knives appeared, and the red hardness was improved. It can be cut at 500~600 °C. The cutting speed is increased by 3 to 4 times. Subsequently, tungsten carbide cobalt carbide was produced, which can be processed at a cutting temperature of 800~1000 °C. The cutting speed is 4~10 times higher than that of ordinary high-speed steel, and it can process a variety of difficult-to-machine materials, greatly improving the metal cutting process. Labor productivity has promoted the development of the machinery industry.

Henan is an important base for superhard materials in China, and is the birthplace and industry center of Yuyao in the domestic superhard materials and products industry. In particular, the superhard materials industry in Henan Province with Zhengzhou as the core has many advantages in talents, technology, information, products, industry, market and industry management services. In December 2002, it successfully applied for the national superhard material industry base. Zhengzhou High-tech Zone has become China's first and only national super-hard material industry base. Zhengzhou Bote Hard Materials Co., Ltd. (hereinafter referred to as Bot Company) was established under such a historical background.

First, cemented carbide tools

Coated cemented carbide tools that appeared around 1968 and their rapid development are the most important developments in cemented carbide, which is particularly important for the promotion of indexable inserts, which has pushed the level and ability of cutting forward. A big step. Coated carbide inserts can process a variety of metal box non-metallic materials, compared with non-coated blades, can increase cutting speed by 30~40%, tool durability is increased by two times, and cutting efficiency is improved by more than 80%. It should be specially pointed out that in recent years, coating technology has entered the field of super-hard materials, such as cubic boron nitride (CBN) and diamond coating technology has been successful in 1972, coated cubic boron nitride tools are mainly used Cutting hardened steel, high speed steel, stainless steel and superalloy.

Second, ceramic knives

The emergence and development of ceramic tool materials has raised the ability and level of machining to a new level. Especially in the past ten years, there has been considerable progress in terms of tool performance, product type and use. Alumina ceramic cutters and silicon nitride ceramic cutters have high hardness, good wear resistance, heat resistance and chemical inertness. At 1200~1300°C, the cutting performance still does not change. The steel can be cut at a speed of 250~400m/min. , cast iron at speeds of 800~1000m/min. The cutting speed is 1~2 times higher than that of cemented carbide, the tool durability is 4~9 times higher, the process labor is reduced by 40%, and it can be used for continuous turning and milling, which has high productivity. For example, cutting cast iron at a speed of V = 390 m/min, the durability of the ceramic tool is 5 times that of the tungsten carbide-based cemented carbide; and it is 3 times that of the titanium carbide-based cemented carbide. When machining 40Cr steel, the durability of ceramic tools is 5-6 times that of cemented carbide. Ceramic inserts have replaced carbide-coated blades for cast iron flywheels, and the results are obvious.

Third, super hard tools

In 1957, GE Corporation of the United States first synthesized cubic boron nitride (CBN). It is a superhard tool material with many unique advantages. Hardness up to HV8000~9000, close to diamond; cutting at temperatures up to 1400~1500 °C, allowing higher cutting speeds, has great potential for further productivity. In 1972, polycrystalline diamond and polycrystalline cubic boron nitride were widely used in industry, which made the metal cutting industry and the development of the contemporary materials industry more adaptable. Polycrystalline diamond can process non-ferrous metals such as copper and aluminum, as well as non-metallic materials such as wear-resistant plastics and hard rubbers, and hard and brittle materials such as hard alloys, ceramics and fiberglass lamps, which are 20 to 200 times more durable than cemented carbide tools; The processing efficiency and precision are far from being comparable to those of cemented carbide tools, and the cutting performance is even better than natural diamond. Polycrystalline cubic boron nitride can process hardened steel, chilled cast iron and nickel-based, cobalt-based alloys, and can also be spray-welded and sprayed. For example, a surface with a hardness of HRC55 sprayed with chromium nitride can be processed with only 3 pieces of hard alloy and 1000 pieces of cubic boron nitride with a surface roughness of Ra0.63~1.25um.

These two superhard tool materials have been made into indexable inserts for use in cars and milling. For finishing and semi-finishing HRC40~70 hardened steel, the cutting amount is cutting speed 80~800m/min, feed per tooth is 0.005~0.15mm, cutting depth is 0.05~1.5mm, surface roughness Ra0.2um, Finished cast iron can also use a higher cutting amount, cutting efficiency is 1.5 to 3 times higher than cemented carbide. For milling over-eutectic silicon-aluminum alloy, the cutting depth can reach 9mm and the surface roughness is Ra0.42~1.0um. The development of super-hard tool materials has raised the level of machining to a new level, cutting at high speeds above 1000 m/min, and machining workpieces with hardness up to HRC70.

summary:

Who is the main tool for ceramic tools and super-hard materials? Compared with other tool materials, the most important feature of ceramic tools is high hardness and high temperature performance, so under high-speed cutting, the tool still has good wear resistance and heat resistance. Since the strength and fracture toughness of ceramic tools are still lower than that of cemented carbides, the resistance to breakage during intermittent cutting has yet to be improved. Ceramic tools are less than the toughness and hardness of cubic boron nitride tools. Therefore, according to the difference of hardness and toughness, ceramic tools are better choices when quenching steel workpieces with cutting hardness below 50HRC and small depth of cut and small feed. Cubic boron nitride tools are more suitable for workpiece hardness higher than 50HRC. Not only continuous cutting, but also capable of handling harsh environments, continuous to intermittent cutting, it can be said that cubic boron nitride tools can replace ceramic tools to process difficult materials, if you are using ceramic tools to process automotive engines, cars Gears, gearboxes, bearing raceways, wind turbines, industrial pumps, etc., it is recommended to use cubic boron nitride blades, which is not harmful to improve processing productivity and reduce processing costs. Zhengzhou Bote Company provides a complete set of processing solutions, which can be shared with users for successful processing cases for defective and difficult workpieces. For the processing of different materials, Bot tailored an economical and most feasible solution. (This article refers to the "ceramic tool cutting process")

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