Affiliation:
1. Centre for Advanced Jet Engineering Technologies (CaJET) School of Mechanical Engineering Shandong University Jinan 250061 P. R. China
2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture Ministry of Education Shandong University Jinan 250061 P. R. China
3. National Demonstration Center for Experimental Mechanical Engineering Education Shandong University Jinan 250061 P. R. China
4. Additive Manufacturing Research Center of Shandong University of National Engineering Research Center of Rapid Manufacturing Jinan 250061 P. R. China
5. Technical Division Sichuan Innov Aviation Technology Co., Ltd Sichuan 610081 P. R. China
Abstract
Ceramic tool materials possess a wide range of potential in machining nickel‐based superalloys due to their superior wear resistance, high‐temperature hardness, and strong chemical stability. Herein, a structural optimization scheme of self‐developed silicon nitride ceramic end mill based on stiffness enhancement and performance improvement is proposed, and the key geometric angular parameters scope of the self‐developed ceramic end mills are prioritized via the finite‐element simulation method. Through precision grinding manufacturing and sandblasting pretreatment, the cutting performance and tool wear behavior of three optimized self‐developed silicon nitride ceramic end mills (called S4‐1, S4‐2, S4‐3 respectively) are comprehensively analyzed in comparison, including cutting force, milling temperature, surface quality, and tool life. The results indicate that the cutting force and cutting temperature of all the optimized ceramic end mills are effectively restrained compared with the nonoptimized ceramic tool(S4), and the final workpiece surface roughness is significantly reduced. Further, better surface quality can be obtained by optimized ceramic mills. In terms of tool life, ceramic end mill with optimized construction in best can be increased by up to 1.9 times. The wear mechanism and pattern of the three optimized ceramic milling tools are similar, which is adhesive wear, diffusion wear, and notch wear. Overall, the effectiveness of the optimization scheme for ceramic end mill is successfully verified.
Funder
National Natural Science Foundation of China
Natural Science Foundation of Shandong Province
Subject
Condensed Matter Physics,General Materials Science