Self-Lubricating Tungsten Carbide Inserts for Continuous Dry Machining Operations

Lenane la litaba

Selelekela

Baenjineri ba lihlahisoa ba lula ba batlana le litsela tsa ho etsa hore tšebetso ea machining e be kapele, e theko e tlaase, hape e be tala. Liindasteri tse kang tsa sefofane, likoloi, le tlhahiso ea lisebelisoa tsa bongaka li itšetlehile haholo ka machining ho bopa lisebelisoa tse matla haholo hore e be likarolo tse nepahetseng. Ka tloaelo, maro a sehang a 'nile a sebelisoa ho boloka lisebelisoa li pholile, ho fokotsa khohlano le ho lelefatsa bophelo ba lisebelisoa. Empa maro ana a tla le thoto—tšilafalo ea tikoloho, likotsi tsa bophelo bo botle ba basebetsi le tsamaiso e bitsang chelete e ngata ea ho lahla. Ke hona moo li-self-lubricating tungsten carbide tse kenang teng, tse fanang ka mokhoa oa ho kenya lisebelisoa tse thata tsa mochine ntle le bohlasoa ba metsi. Lisebelisoa tsena li na le mafura a hahelletsoeng ka hare ho ona joalo ka calcium fluoride kapa molybdenum disulfide, e lumellang machining a sa khaotseng a omme ha a ntse a boloka ho khathala le mocheso. Sengoliloeng sena se kenella ka har'a hore na lisebelisoa tsena li sebetsa joang, ts'ebeliso ea tsona ea lefats'e la 'nete linthong tse kang li-implants tsa bongaka, likarolo tsa enjene ea jete, le likarolo tsa enjene ea koloi, le hore na lienjiniere li ka li sebelisa joang. Re tla akaretsa mahlale, mehlala e sebetsang, litšenyehelo, le malebela a mohato ka mohato ho thusa mabenkele ho etsa phetoho.

Mechine e omileng—ho seha ntle le maro—e ntse e eketseha ha lik’hamphani li tobane le khatello ea ho fokotsa litšila le ho finyella melao ea tikoloho. E felisa tlhokahalo ea litanka tsa mokelikeli, lipompo le lisebelisoa tsa ho lahla, tse ka bolokang chelete e ngata le ho fokotsa ho opeloa ke hlooho. Empa ntle le maro, lisebelisoa li tobana le mocheso o matla le likhohlano, haholo ha li seha lisebelisoa tse kang titanium kapa tšepe e thata. Lisebelisoa tsa ho itlotsa li sebetsana le sena ka ho ntša mafura moo sesebelisoa se kopanang le mosebetsi, ho senya le ho boloka mocheso o le tlase. Ho latela liphuputso tsa morao-rao, re tla hlahloba hore na lisebelisoa tsena li sebetsa joang, re arolelane mehlala ho tsoa indastering, le ho fana ka likeletso tse sebetsang mabapi le litjeho le ho seta ho thusa lienjiniere ho fumana liphetho.

Saense ea ho Itlatsa Tungsten Carbide Insets

Tungsten carbide, eo hangata e kopantsoeng le cobalt e nyane, ke lisebelisoa tsa ho seha hobane e thata haholo ebile e khona ho mamella mocheso o phahameng. Lisebelisoa tsa ho itlotsa ka botsona li e phahamisa ka ho eketsa lisebelisoa tse tiileng tse kang calcium fluoride (CaF2), molybdenum disulfide (MoS2), kapa esita le graphene ka har'a motsoako. Litlolo tsena li etsa lesela le thellang nakong ea ho sebetsa ka mechine, li fokotsa khohlano le mocheso ntle le ho hloka lerotholi la lero.

Mona ke kamoo e sebetsang kateng: ha sesebelisoa se khaola, mocheso le khatello sebakeng sa ho kopana li etsa hore setlolo se tlotse, se etsa filimi e tšesaane, e thellang. Ka mohlala, CaF2 e lula e tsitsitse mochesong o bataolang—ho fihla ho 1000°C—e etsa hore e be molemo bakeng sa mesebetsi e boima. MoS2, ka sebopeho sa eona se nang le lera, e thella habonolo maemong a omileng, ha graphene e tlisa phallo e phahameng ea mocheso le ho tiea. Mehaho ena e etsa hore lisebelisoa li atlehe ka mochine o omileng, moo lisebelisoa tse tloaelehileng li neng li tla fela ka potlako ka lebaka la mocheso le khatello ea kelello.

Kamoo Li Etsoang Kateng

Ho kenya lintho tsena hangata ho kopanyelletsa phofo ea metallurgy—ho kopanya tungsten carbide, cobalt le lubricant powders, ho li hatella hore li be sebōpeho, le ho li baka mochesong o phahameng ho etsa sesebelisoa se tiileng. Mokhoa o mong ke oa ho roala lintho tse kenngoeng ka mokhoa o tloaelehileng ka litlolo tse sebelisang mekhoa e kang chemical vapor deposition (CVD) kapa physical vapor deposition (PVD). Metallurgy ea phofo e hasanya lubricant ka ho lekana ho pholletsa le sesebelisoa, e leng ntho e ntle bakeng sa mesebetsi e thata, ha litlolo li sebetsa hantle bakeng sa libopeho tse nepahetseng kapa tse rarahaneng.

Lithuto tsa morao-rao li bontša tsoelo-pele e thabisang. Pampiri e 'ngoe e fumane hore ho eketsa 5% CaF2 ho li-tungsten carbide ho li kenya ho li etsa hore li be matla le ho se rate ho apara ha li seha tšepe ea AISI 1020 ntle le maro. Boithuto bo bong bo sebelisitse graphene ho kenngoeng ka mongolo, ho fokotsa mocheso ka 20% le matla ka hoo e ka bang 40% ha ho etsoa mochini oa Inconel 713C. Liphuputso tsena li bonts'a hore na lisebelisoa tsa ho itlotsa li ka sutumelletsa mochini o omileng maemong a macha joang.

Lisebelisoa tsa 'Nete tsa Lefatše

Lisebelisoa tsena li etsa maqhubu liindasteri tse hlokang ho nepahala le ho tšoarella. Ha re shebeng mehlala e meraro: li-implants tsa bongaka, li-blade tsa turbine tsa sefofane, le likarolo tsa enjene ea likoloi.

Li-implants tsa Bongaka

Ho etsa li-alloys tsa titanium joalo ka Ti-6Al-4V bakeng sa li-implants tsa letheka kapa lengole hoa qhekella. Thepa e matla, e tsamaisa mocheso hampe, 'me e hloka sebaka se hloekileng haholo ho qoba tšoaetso. Mechine e omileng e loketse ho tlola masalla a mokelikeli, empa ho thata ho lisebelisoa. Lintho tse itlhophang tse nang le MoS2 kapa likoti tsa graphene li pholosa bophelo mona. K'hamphani e 'ngoe ea lisebelisoa tsa bongaka e etsang likarolo tsa botšehali e bone bophelo ba lisebelisoa bo tlola ka 30% e sebelisa li-insets tsa CaF2-doped. Lubricant e ile ea fokotsa khohlano, ea boloka mocheso o le tlase, 'me ea fana ka pheletso e bonolo, e leng bohlokoa bakeng sa li-implants tse hlokang ho lekana hantle' meleng.

Keletso: Bakeng sa li-implants, e-ea ho kenya ka 5-10% CaF2 'me u boloke lebelo la ho itšeha pakeng tsa 80-120 m / min ho leka-lekanya bophelo ba lisebelisoa le boleng ba holim'a metsi. Lekola lisebelisoa hangata ka microscope ho tšoasa esale pele, kaha le liphoso tse nyane li ka senya mamello ea li-implant.

Aerospace Turbine Blades

Li-blade tsa turbine lienjineng tsa jete, tse atisang ho etsoa ka li-superalloy tse thehiloeng ho nickel joalo ka Inconel 718, li thata ho li sebelisa hobane li thata ebile li thatafalloa ho feta nakong ea ho seha. Ho li omisa ntle le ho chesa lisebelisoa ke phephetso. Lintho tse kentsoeng tse nang le bokaholimo bo hlophisitsoeng le litlolo tsa graphene li bontšitse litholoana tse ntle. Ketsahalong e 'ngoe, ho etsa li-blade tsa Inconel 718 tse nang le lisebelisoa tse koahetsoeng ke graphene li ile tsa khaola liaparo tsa lisebelisoa ka 2.3% e nyenyane empa e le ea bohlokoa le ho ntlafatsa boreleli holim'a metsi ka ho feta 20%. Sena se ne se bolela li-blade tse matla tse tšoarellang nako e telele lienjineng.

Keletso: Sebelisa lintho tse kentsoeng ka PVD bakeng sa li-blade tsa turbine ho fumana tšireletso ea lubricant ka libopeho tse rarahaneng. Khomarela lebelo la ho itšeha la 100–150 m/min le litefiso tse tlase tsa phepo (0.1 mm/rev) ho qoba ho chesa haholo. Ka mor'a ho sebetsa ka mochine, sebelisa microscope ea elektronike e hlahlobang (SEM) ho bona mekhoa ea ho apara pele ho nako.

Likarolo tsa Enjine ea Likoloi

Bakeng sa likarolo tsa enjene ea koloi tse kang crankshafts kapa camshafts, tse entsoeng ka litšepe tse thata joaloka AISI 4340, mabenkele a hloka lisebelisoa tse tšoarellang le ho boloka litšenyehelo li le tlase. Lisebelisoa tsa ho itlotsa ka CaF2 kapa MoS2 li thusa ka ho fokotsa ho roala le ho etsa hore ho be bonolo ho sebetsana le li-chips maemong a omileng. Semela se le seng sa likoloi se sebelisang lisebelisoa tsa WC-10Co-5CaF2 se bone bophelo ba lisebelisoa bo eketseha ka 25% haretelehaAISI 1020 tšepe, e nang le li-chips tse boreleli le nako e fokolang ea ho tloha liphetohong tsa lisebelisoa.

Keletso: Khetha lisebelisoa tse nang le 10-12% cobalt bakeng sa boima le CaF2 bakeng sa ho thella. Boloka li-parameter tsa ho seha li tsitsitse-ha re re, lebelo la 100 m/min le botebo ba limilimithara tse 0.5-bakeng sa liphetho tse tsitsitseng. Shebella chip buildup ho qoba libaka tse makukuno, tse ka senyang karolo ea boleng.

Karohano ea Litšenyehelo

Ho fetohela linthong tse itlholisang ho bitsa chelete e ngata esale pele, empa ho lefa ka nako. Karohano ke ena:

Litšenyehelo tsa Lisebelisoa: Lintho tsena tse kentsoeng li na le theko ea 20–30% ho feta tse tloaelehileng. Kenyelletso ea WC-10Co-5CaF2 e ka bitsa $15–$20 e le 'ngoe, ha e bapisoa le $10–$12 bakeng sa ho kenya kamehla.
Thepa: Mechine e omileng ha e hloke lisebelisoa tsa mokelikeli, kahoo litšenyehelo tsa ho seta li tlase. Empa ho ntlafatsa ho ea ho mechini e nepahetseng ea CNC bakeng sa liphetho tse ntle ho ka tsamaisa $50,000–$100,000.
Tool Life Savings: Lintho tsena tse kentsoeng li nka nako e telele ho 20–50%, li fokotsa tse ling. Lebenkele la lisebelisoa tsa bongaka le bolokile $10,000 ka selemo ka ho theola liphetoho tsa lisebelisoa ho tloha ho 10 ho isa ho 6 ka khoeli.
Poloko ea Tikoloho: Ho tlola maro a boloka $5,000–$20,000 selemo le selemo ha u li reka, u li boloka le ho li lahla, ho itšetlehile ka boholo ba lebenkele.

Lebenkeleng le leng la machining a Inconel 718, tse kentsoeng ka graphene li theotse litšenyehelo ka 15% ka lebaka la bophelo bo bolelele ba lisebelisoa le tšebeliso e tlase ea matla. Setsi sa likoloi se bolokile 10% ea litšenyehelo tsa tlhahiso ka ho kenya CaF2, e khutlisa litšenyehelo tse phahameng tsa lisebelisoa ka likhoeli tse tšeletseng.

Keletso: Etsa tlhahlobo ea melemo ea litšenyehelo, ho lekanya bophelo ba lisebelisoa, bophahamo ba tlhahiso, le ho boloka metsi. Lekola kenya ka tekanyo e nyane pele ho netefatsa ho boloka chelete pele o kena kaofela.

Mehato ea ho Qala

Mokhoa oa ho tlisa lintho tse itlholisang lebenkeleng la hau ke tsena:

Khetha Kenyelletso e Nepahetseng: Bapisa kenyelletso le boitsebiso ba hao. Sebelisa MoS2 kapa graphene bakeng sa titanium, CaF2 bakeng sa litšepe. Buisana le barekisi mabapi le mefuta e tloaelehileng ea motsoako.
Etsa Mechini: Lekola mechini ea CNC bakeng sa mochini o omileng. Sepheo sa lebelo la 100-150 m / min, lijo tsa 0.1-0.2 mm / rev, le botebo ba 0.5-1 mm.
Kenya Lisebelisoa: Kenya lintho tse kentsoeng ka mokhoa o sireletsehileng ka har'a litšepe ho qoba ho thothomela. Sebelisa sepane sa torque ho thibela ho petsoha ho tloha ho tiea ho feta tekano.
Matha Liteko: Qala ka lihlopha tse nyane ho daela ho li-setting. Sheba ho roala ha lisebelisoa, ho qeta holimo, le sebopeho sa chip u sebelisa lisebelisoa tse kang SEM kapa profilometers.
Hlokomela Phela: Sebelisa li-sensor ho shebella matla a ho itšeha le mocheso nakong ea ho matha. Fetola litlhophiso haeba lintho li chesa haholo kapa li roala li-spikes.
Hlahloba Kamehla: Sheba lintho tse kentsoeng ka li-microscopes tsa optical hore na li felile. Li fetolele ha flank wear e fihla ho 0.3 mm ho boloka boleng bo holimo.
Eketsa Holimo: Hang ha liteko li shebahala li le ntle, qala tlhahiso e felletseng. Koetlisa sehlopha sa hau ka mochini o omileng ho boloka lintho li le boreleli.

Keletso: Lekola mochini o le mong pele, ho latela metrics joalo ka bophelo ba sesebelisoa le pheletso ea bokaholimo. Sebelisa lintlha ho hlophisa hantle pele u atolosetsa mecheng e meng.

Mathata le Litokiso

Lisebelisoa tsa ho itlotsa ha lia phethahala. Litsenyehelo tse phahameng tsa pele li ka hlaba, empa chelete e bolokiloeng bophelong ba lisebelisoa le litšenyehelo tsa mokelikeli hangata lia lekana. Taba e 'ngoe ke ho fumana chelete ea lubricant hantle - haholo e fokolisa sesebelisoa, ha nyane haholo ha e tlotse ka ho lekaneng. Liphuputso li fana ka maikutlo a hore 5-10% ea lubricant e otla sebaka se monate. Mesebetsi e phahameng ea mocheso, joalo ka ho seha Inconel, e ka theola mafura a mang. Ho sebelisa tse thibelang mocheso joalo ka CaF2 kapa ho kopanya mafura (mohlala, MoS2 le graphene) hoa thusa.

Keletso: Sebetsa le litsebi tsa thepa ho hlophisa metsoako ea lubricant bakeng sa mesebetsi ea hau. Koetlisa basebetsi kamehla ho sebetsana le lisebelisoa ka nepo le ho fumana molemo o moholo ho tsona.

Qetello

Li-self-lubricating tungsten carbide tse kenyang li fetola papali bakeng sa machining a omileng. Ka ho kenya mafura a kang CaF2, MoS2, kapa graphene, ba fokotsa likhohlano, ba matlafatsa bophelo ba lisebelisoa, 'me ba fana ka libaka tse betere ho liindasteri tse kang tsa bongaka, sefofane le likoloi. Ho tloha ho li-implants tsa titanium ho ea ho li-blade tsa jet ho ea ho li-crankshafts tsa koloi, lisebelisoa tsena li paka bohlokoa ba tsona lits'ebetsong tse thata. Theko ea pele e phahame, empa ho boloka nako e telele ea lisebelisoa, nako e fokolang, 'me ha ho na maro a etsang hore e be bethe e bohlale. Ka moralo o hlakileng—ho khetha ntho e kentsoeng ka nepo, ho beha mechine le ho hlahloba ka hloko—mabenkele a ka sebetsana le mathata ’me a bona melemo ea sebele. Ha tlhahiso e ntse e tsoela pele bakeng sa mekhoa e metle, e nepahetseng haholoanyane, lisebelisoa tsena li behiloe ho fetoha setsi sa mantlha mabenkeleng a sejoale-joale.

Q&A

Q1: Ke eng e khethollang li-self-lubricating tungsten carbide tse kenyelletsoang ho tloha ho tse tloaelehileng?
A1: Li na le lisebelisoa tse tiileng tse kang CaF2 kapa MoS2, tse fokotsang khohlano le ho apara nakong ea mochine o omileng, ho felisa tlhokahalo ea li-coolants tsa metsi.

Q2: Na lisebelisoa tsee li ka sebetsana le thepa efe kapa efe?
A2: Li ntle bakeng sa lisebelisoa tse thata joalo ka titanium, li-alloys tsa nickel, le litšepe tse thata. Khetha lubricant e thehiloeng ho lisebelisoa bakeng sa liphello tse ntle.

Q3: Nka lokafatsa litšenyehelo tse ling joang?
A3: Sheba melemo ea bophelo ba lisebelisoa (20–50%), nako e fokolang, le ho boloka litšenyehelo tsa metsi. Liteko tse nyane li ka bonts'a hore na letsete le lefella lebenkele la hau.

Q4: Ke eng e ka senyehang ka ho kenya lintho tsee?
A4: Ho senya kapa ho apara ho ka etsahala, haholo-holo ka lebelo le phahameng. Ntlafatsa lebelo (100–150 m/min) 'me u sebelise mafura a thibelang mocheso joaloka CaF2 ho fokotsa likotsi.

Q5: Ke boloka tlaleho ea ts'ebetso joang mochining o omileng?
A5: Sebelisa li-sensor bakeng sa matla a nako ea nnete le data ea mocheso. Lekola lisebelisoa tsa morao-rao ka li-microscopes kapa SEM ho ts'oara le ho lokisa litlhophiso.

Litšupiso

Tekolo ea ts'ebetso ea lisebelisoa tsa ho itšeha tse itšehang ka tungsten carbide
Muthuraja, P., Senthilvelan, T.
Journal of Engineering Manufacture, 2016
Liphuputso tsa Bohlokoa: Lisebelisoa tsa WC-10Co-5CaF₂ li bonts'itse ho ntlafala ha antifriction le ho roala ho hanyetsa ha ho bapisoa le WC-10Co e tloaelehileng.
Mokhoa: Ho etsoa ha metallurgy ea phofo le liteko tsa ho itšeha.
Tlhaloso: Muthuraja le Senthilvelan, 2016, maqephe 1375-1394
https://www.semanticscholar.org/paper/Performance-evaluation-of-a-tungsten-carbide%E2%80%93based-Muthuraja-Senthilvelan/655246ce2f57b1e9e607c7343820b6ff30c65388
Mokhoa o tsitsitseng oa ho omisa oa tšepe e sa tsitsang o nang le lisebelisoa tsa ho seha tsa Tungsten Carbide ka Microwave.
Babe, IB, Gupta, K., Chaubey, SK
Mechini e menyenyane, 2023
Liphuputso tsa Bohlokoa: Kalafo ea microwave e matlafalitse ho thatafala le sebopeho sa microwave, e fokotsa ho roala ha lisebelisoa le ho ntlafatsa boleng ba bokaholimo ha o fetola SS 316.
Mokhoa: Taguchi L9 orthogonal array design, multiperformance optimization, SEM analysis.
Tlhaloso: Babe et al., 2023, pp. 1148
https://doi.org/10.3390/mi14061148
Ho Ntlafatsa Ts'ebetso ea Machining ea Lisebelisoa tsa CNC tse Apesitsoeng ka Liaparo tsa Carbon tse kang Taemane tlasa Tikoloho e Omileng ea Seha
Rana, R., Krishnia, L., Murtaza, Q., Walia, RS
Journal of Engineering Research, 2021
Liphuputso tsa Bohlokoa: Liaparo tsa DLC li ekelitse boima ka 53%, ho ntlafala ha moaparo le ho qeta ka holim'a maemo a machining a omileng.
Mokhoa: Ho roala ka mocheso oa CVD ho sebelisa bagasse ea 'moba, Raman spectroscopy, XRD, SEM, TOPSIS optimization.
Tlhaloso: Rana et al., 2021, leqepheng la 142-152
https://pdfs.semanticscholar.org/a610/52ce2a3de80013863263c6e88cb6c1b93699.pdf
- Tungsten carbide
- Mechini e ommeng