In recent years, with the development of materials engineering and the continuous emergence of new materials, in the area of ​​aerospace and large-scale processing, as the degree of adoption of difficult-to-process materials has deepened and composite materials continue to emerge, along with the With the popularization of large-scale and digitized intelligent processing technologies, high-speed processing and super-long-time processing increasingly occupy an absolute position. The emergence of ceramic and cermet tools is precisely the urgent need for high-speed and high-efficiency machining in the manufacturing industry. For "Made in China" in the transition period, with the prior accumulation of technology and technological exploration, mass production of domestically produced large aircraft such as the "C919 large passenger plane" and "Yun-20 strategic transport plane" will be produced as a representative. In 2017, China's demand for ceramic and cermet cutting tools will surely have a big increase in the urgent need of the upgrading of materials technology and manufacturing processes.
At the same time, with the combination of tool technology and machine tool technology, workpiece materials and tool materials promote each other, and the aerospace manufacturing industry continues to develop. It can be said that the continuous development of tool materials is the driving force for the continuous development of aerospace manufacturing. At present, there are as many as 1,000 types of tool materials that are widely used in the aerospace manufacturing industry. According to the tool materials, there are no more than the following categories: Tool Steel (Carbon Tool Steel, Alloy Tool Steel, High Speed ​​Steel), Carbide Alloy , ceramics and superhard cutting material. Carbon tool steel is suitable for manufacturing hand tools, and carbon tool steel T10A and T12A are widely used.
In aerospace manufacturing, cemented carbide tools account for the largest proportion. Carbide cutting tools are the dominant tool in aeronautical manufacturing and they have a wide range of applications and are dominant in CNC tool materials. Cemented carbide becomes the main tool material, which makes the cutting process realize the transition to carbide age. Due to the different performance characteristics of different grades of cemented carbide, its application range is also different. Carbide can be used not only for the manufacture of various machine tools, but also for the manufacture of integral end mills, reamers, taps and drills. Cemented carbide tools are classified into ordinary hard alloys, coated hard alloys, ultra-fine grain carbides, and carbon (nitrogen) titanium-based hard alloys.
YT cemented carbide has most of the good properties of YG and YW, and is widely used in aerospace manufacturing. The coated cemented carbide has a higher hardness, wear resistance, and heat resistance than the substrate and is widely used. Ultrafine particle cemented carbide can be widely used for interrupted cutting. Carbon (nitrogen) titanium-based hard alloys are mainly used for the finishing and semi-finishing of continuous surfaces of steel parts.
With the development of the new technology revolution, it is required to continuously increase the cutting productivity and reduce the production cost. In particular, the development of CNC machine tools requires the development of new cutting tools that are faster and harder than carbide cutting tools. Recently, various new hard-to-cut materials with high strength, high hardness, corrosion resistance, wear resistance and high temperature resistance have been increasingly available. According to the estimates of the literature, these materials have accounted for more than 50% of the total number of processed materials in the world. Carbide cutting tools cannot handle many of these new materials. On the other hand, the output of cemented carbides in the world has reached 20,000-25,000 tons. Each year consumes a large amount of metals such as W, Co, Ta, and Nb. The mineral resources of these metals are declining. Prices have risen. It will take a few days before consumption. Some resources will be exhausted. Ceramic knives are developed in this context.
As early as 1912-1913, alumina ceramic cutters appeared in England and Germany, but its application in production began in 1950. Because of its low strength and toughness, it is limited to continuous cutting finishing for a long period of time, and the cutting speed and feed rate are low. It was not until 1968 that the second-generation ceramic cutting tool—aluminum oxide composite tool—has been significantly improved in strength and toughness compared to alumina tools, and can cut various workpieces at a high speed and a large feed rate. Has been more widely used. From the late 1970s to the early 1980s, the third generation of ceramic cutting tools - silicon nitride ceramic tools. This ceramic knife has higher toughness, impact resistance, high temperature strength and thermal shock resistance than composite alumina tools. The output of ceramic blades in various industrialized countries has grown rapidly.
China began mass production of composite alumina blades in the mid-1960s, and the current annual production volume is 14-15 million. Silicon oxide ceramic inserts have been studied since the mid-1970s and cannot meet their needs due to poor performance. In recent years, with the continuous deepening of research on high-temperature structural ceramics, the performance of silicon nitride ceramics has been greatly improved, and silicon nitride ceramic tools have rapidly developed in China.
Although the research level of China's ceramic cutting tools is not worse than that of foreign countries, the actual application development is slow. According to relevant data, at present, the proportion of domestic ceramic tools in the total tool usage does not exceed 1%. Silicon nitride ceramic tool is a new tool that has been widely used in production in recent years. Therefore, there is no mature experience in terms of tool geometry, cutting amount, and use technology. China's ceramic tools in the indexing tool in the proportion is very small, the annual output is less than 0.1% of carbide. From the cutting performance point of view, China's ceramic tools are developing to high hardness alloy cast iron rough machining, intermittent cutting direction.
Ceramic tool features:
1. It has good wear resistance and can process high-hard materials that traditional cutting tools are difficult to process or can't process at all. Therefore, it can eliminate the power consumed by annealing processing; therefore, it can also increase the hardness of workpieces and extend the service life of machinery and equipment;
2. It can not only perform rough and fine processing on high hardness materials, but also can perform large impact processing such as milling, planing, interrupted cutting, rough blanking and roughing.
3, ceramic blade cutting and metal friction, cutting is not easy to bond on the blade. Not easy to produce built-up edge. Plus can be high-speed cutting. Therefore, when the conditions are the same, the roughness of the workpiece table is relatively low.
4. The tool life is several times or even dozens of times higher than traditional tools, which reduces the number of tool changes during machining and ensures the small taper and high precision of the machined workpiece.
5, high temperature, good red hardness. It can be continuously cut at 1200 degrees Celsius. Therefore, the cutting speed of the ceramic tool can be much higher than that of the cemented carbide. It can carry out high-speed cutting or realize "milling, milling and grinding". The cutting efficiency is 3 to 10 times higher than traditional cutting tools. It can save labor hours, electricity, machine tools, 30-70% or more.
6, silicon nitride ceramic tool is the main raw material is rich in natural nitrogen and silicon, used to replace carbide, can save a large number of W, Co, Ta and Nb and other important metals.
At present, the application of ceramic tools in China is still in its infancy, and the actual application development is slow. Ceramic tools are mainly used for rough machining of hard-to-cut workpieces. It is not a long time for the aerospace manufacturing to promote the use of ceramic tools. It is necessary to accumulate experience in the geometric parameters, cutting amount, and usage technology of ceramic tools. Ceramic materials have higher hardness, hot hardness, and wear resistance than cemented carbide. Ceramic cutters are superior to hard alloys in terms of chemical stability, oxidation resistance, etc. They are ideal for dry continuous high-speed cutting of high-temperature alloys, hardened steels, bearing steels, high-strength steels, and other difficult-to-machine materials. There are many applications of high-temperature alloys in aero-engines, and there are many parts with shafts, which is where ceramics tools can play their advantages. It is entirely feasible to achieve high-efficiency machining and replace some carbide tools with ceramic tools. Ceramic knives are not universal knives, and they can only be used to their advantage if they are used correctly.
Global ceramic tool brand list:
Delier - Germany Founded in 1818, it is a German high-tech engineering group with unique advantages in material technology.
Sumitomo - Japan Sumitomo Sumitomo is one of the largest integrated tool manufacturers in Japan and has over 100 years of manufacturing experience in manufacturing tooling.
Sandvik - Sweden Founded in Sandviken, Sweden in 1862
KOMET - Germany is located in the top ranks of the world
Hymer - Germany
TUNGALOY - Japan
Mitsubishi - Japan
Teguci - South Korea's largest integrated tool maker
Unimog (now purchased by Kyocera) - Denmark
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