基于冲击波传导理论的层状陶瓷刀具设计及其多尺度力学行为研究

Laminated ceramic cutting tool based on shock wave transfer theory and its research on multiscale analysis of mechanical properties are proposed in this research in order to improve the tool edge chipping resistance of ceramic cutting tool used in high speed cutting and intermittent cutting. The shock resistance, interface design, microstructure, mechanical properties in room temperature and elevated temperature, friction and wear and dry machining characteristics of laminated ceramic cutting tool will be researched. The shock resistance models of laminated ceramic cutting tool will be established based on wave transfer theory. The relationship between microstructure and mechanical properties of laminated ceramic cutting tool will be simulated using multiscale theory. High temperature mechanical property prediction model will be built to reveal the relationship between high temperature mechanical properties, dynamic fatigue properties, cutting performance and failure mode of laminated ceramic cutting tool. The nonlinear model of tribology of laminated ceramic cutting tool will be established to reveal the relationship between friction experiment and cutting experiment. The relation of the models established from the above will be analyzed to research the relationship between mechanical properties in room temperature and elevated temperature, dynamic fatigue properties, friction and wear behavior and cutting reliability of laminated ceramic cutting tool. As a result, the design theory and fabrication technology of laminated ceramic cutting tool based on shock wave transfer theory will be proposed to provide theoretical and technical basis for the preparation of high performance laminated ceramic cutting tool materials.

针对陶瓷刀具高速切削特别是断续切削时易发生崩刃等问题，本项目提出了基于冲击波传导理论的层状陶瓷刀具及其多尺度设计，拟以层状陶瓷刀具的抗冲击性能、界面设计、微观组织结构、室温和高温力学性能、摩擦磨损、干切削特性等为研究对象。建立层状陶瓷刀具抗冲击性能的波传导理论模型，进行基于材料微观组织的多尺度力学行为模拟，揭示其微观结构与力学性能之间的关系。构建层状陶瓷刀具高温力学性能预测模型，揭示其高温力学性能、动态疲劳性能与刀具切削性能和失效形式的关联关系。构建从宏观到微观的干切削层状陶瓷刀具的非线性摩擦学模型，建立摩擦实验和切削实验之间的关系模型。并探究各模型之间的内在联系，揭示层状陶瓷刀具材料常温、高温力学性能、动态疲劳特性、摩擦磨损特性、切削可靠性等各种特征之间的关联关系。提出一套完整的基于冲击波传导理论的层状陶瓷刀具设计理论和制备技术，为制备高性能层状陶瓷刀具材料提供理论依据。

针对陶瓷刀具高速切削特别是断续切削时易发生崩刃等问题，本项目提出了基于冲击波传导理论的层状陶瓷刀具及其多尺度设计，提出一套完整的基于冲击波传导理论的层状陶瓷刀具设计理论和制备技术，为制备高性能层状陶瓷刀具材料提供理论依据。研究取得如下结论：①完成了基于波传导理论的层状陶瓷刀具理论建模。通过考虑层状陶瓷刀具材料参数声速比和阻抗率对拉伸波幅值减小的影响情况，达到设计层状陶瓷刀具材料组分、层数和初选材料性能参数的目的；②基于Sih准则预测了裂纹扩展并建立了层间晶界残余应力模型。当层状陶瓷刀具材料叠层的残余应力小于零时候，引起裂纹偏转，该偏转可提高材料断裂韧性。本项目制备的层状陶瓷刀具材料中抵抗裂纹扩展的机制有因热膨胀系数失配导致的残余应力、材料界面情况和断裂能的消耗；③建立了层状陶瓷刀具材料烧结模型；④分析了层状陶瓷刀具材料的动态疲劳行为，其弯曲强度与层状结构、多尺度界面的性能以及残余应力的复杂分布有关；⑤研究了层状陶瓷刀具的高温自修复性能，该材料具有良好的自愈能力，且材料的自修复能力与材料原始弯曲强度残余效应和氧化物含量效应密切相关；⑥进行了层状陶瓷刀具切削温度仿真，基于灰色形态学进行了层状陶瓷刀具切削建模，研究层状陶瓷刀具切削速度、进给量、切削深度等切削参数对加工表面完整性的影响，使得切削参数始终适应刀具磨损的变化，在保证表面完整性的前提下，最大程度的提高层状陶瓷刀具的寿命和加工效率。通过本项目的实施，在Journal of Alloys and Compounds (国际顶级TOP期刊)、Ceramics International和International Journal of materials research国际核心期刊发表论文4篇，其中SCI二区论文2篇，SCI四区论文2篇。研究成果分别获2016和2017年度山东省高等学校科研成果奖三等奖2项，申请国家发明专利14项。本研究对提升我国高速切削刀具技术的基础和应用研究有重要理论和实际价值。