Self-Lubricating Tungsten Carbide Inserts for Continuous Dry Machining Operations

Imenyu Yokuqukethwe

Isingeniso

Onjiniyela abakhiqizayo bahlale bebheke izindlela zokwenza izinqubo zemishini zisheshe, zishibhile, futhi zibe luhlaza. Izimboni ezifana ne-aerospace, ezezimoto, nokukhiqizwa kwemishini yezokwelapha zithembele kakhulu ekwenziweni kwemishini ukuze zilolonge izinto ezisezingeni eliphezulu zibe izingxenye ezinembile. Ngokwesiko, uketshezi lokusika lusetshenziselwa ukugcina amathuluzi epholile, ukunciphisa ukungqubuzana, nokwelula impilo yamathuluzi. Kodwa lolu ketshezi lufika nemithwalo—ukungcoliswa kwemvelo, izingozi zempilo yezisebenzi, nezinhlelo zokulahla ezibizayo. Yilapho okuzifakayo okuzigcobayo kwe-tungsten carbide kungena khona, okuhlinzeka ngendlela yomshini wokwenza izinto eziqinile ngaphandle kokungcola koketshezi. Lawa mathuluzi anezinto zokuthambisa ezakhelwe ngaphakathi njenge-calcium fluoride noma i-molybdenum disulfide, evumela ukwenziwa kwemishini eyomile okuqhubekayo kuyilapho kugcina ukuguga nokushisa kubekiwe. Lesi sihloko singena ngaphakathi kokuthi lokhu kufakiwe kusebenza kanjani, ukusetshenziswa kwakho komhlaba wangempela ezintweni ezifana nezigxivizo zezokwelapha, izingxenye zenjini yendiza, nezingxenye zenjini yemoto, nokuthi onjiniyela bangazisebenzisa kanjani. Sizofaka isayensi, izibonelo ezingokoqobo, izindleko, namathiphu esinyathelo ngesinyathelo ukusiza izitolo zenze ushintsho.

Imishini eyomile—ukusika ngaphandle koketshezi—kuyadlondlobala njengoba izinkampani zibhekene nengcindezi yokusika imfucuza futhi zihlangabezane nemithetho yezemvelo. Iqeda isidingo samathangi aketshezi, amaphampu, nezimiso zokulahla, ezingase zonga imali engathi sína futhi zinciphise ubuhlungu bekhanda. Kodwa ngaphandle koketshezi, amathuluzi abhekana nokushisa okukhulu nokungqubuzana, ikakhulukazi lapho esika izinto ezifana ne-titanium noma insimbi eqinile. Izinto ezizigcoba ngokwazo zibhekana nalokhu ngokukhulula izinto zokugcoba lapho ithuluzi lihlangana khona nendawo yokusebenza, ukuguga okugugayo nokugcina izinga lokushisa liphansi. Kusukela ocwaningweni lwakamuva, sizohlola ukuthi lokhu kufakiwe kusebenza kanjani, sabelane ngezibonelo ezivela embonini, futhi sinikeze izeluleko ezisebenzayo ngezindleko nokusetha ukuze sisize onjiniyela bathole imiphumela.

Isayensi Yokufaka I-Tungsten Carbide Self-Lubricating

I-Tungsten carbide, evame ukuxutshwa nentwana ye-cobalt, iyindlela yokuya ezintweni zokusika amathuluzi ngoba inzima ngendlela emangalisayo futhi ikwazi ukumelana namazinga okushisa aphezulu. Izinto ezizigcoba ngokwazo ziyithatha iyinotshi ngokwengeza izinto zokugcoba eziqinile njenge-calcium fluoride (CaF2), i-molybdenum disulfide (MoS2), noma i-graphene kungxube. Lawa ma-lubricant enza ungqimba olushelelayo ngesikhathi somshini, ukunqanda ukungqubuzana nokushisa ngaphandle kokudinga iconsi loketshezi.

Nansi indlela esebenza ngayo: uma ithuluzi lisika, ukushisa nokucindezela endaweni okuthintana kuyo kwenza isigcobo sigcobe, kwakheka ifilimu elincanyana, elishelelayo. I-CaF2, isibonelo, ihlala izinzile emazingeni okushisa ashisayo—afinyelela ku-1000°C—okuyenza ibe yinhle emisebenzini enzima. I-MoS2, nesakhiwo sayo esinezingqimba, islayida kalula ezimeni ezomile, kuyilapho i-graphene iletha ukuchithwa kokushisa okuphezulu nokuqina. Lezi zakhiwo zivumela okufakwayo ukuthi kuphumelele ekushiseni okomile, lapho amathuluzi ajwayelekile azoguga ngokushesha ngenxa yokushisa nokucindezeleka.

Indlela Enziwa Ngayo

Ukwenza lokhu kufakwa ngokuvamile kuhilela i-powder metallurgy—ukuxuba i-tungsten carbide, i-cobalt, nezimpushana zokuthambisa, ukukucindezela ukuze kube nokwakheka, futhi kubhake emazingeni okushisa aphakeme ukuze kwakheke ithuluzi eliqinile. Enye indlela ukumboza izinto ezijwayelekile zokuthambisa kusetshenziswa amasu afana ne-chemical vapor deposition (CVD) noma i-physical vapor deposition (PVD). I-powder metallurgy isakaza okokugcoba ngokulinganayo kulo lonke ithuluzi, elilungele imisebenzi enzima, kuyilapho izimbozo zisebenza kangcono kumajamo anembile noma ayinkimbinkimbi.

Ucwaningo lwakamuva lubonisa inqubekelaphambili ethile ethokozisayo. Elinye iphepha lithole ukuthi ukungeza u-5% we-CaF2 ekufakweni kwe-tungsten carbide kubenze baqina futhi bangabi lula ukugqokwa lapho kusikwa insimbi ye-AISI 1020 ngaphandle koketshezi. Olunye ucwaningo lwasebenzisa i-graphene ekufakweni okubhaliwe, ukusika amazinga okushisa angaphezu kuka-20% futhi kuphoqa cishe u-40% lapho kwenziwa imishini ye-Inconel 713C. Lokhu okutholakele kubonisa ukuthi izinto ezizigcoba ngokwazo zingaphusha kanjani imishini eyomile iye ezingeni elisha.

Izicelo Zomhlaba Wangempela

Lezi zinto ezifakiwe zenza amagagasi ezimbonini ezidinga ukunemba nokuqina. Ake sibheke izibonelo ezintathu: izimila zezokwelapha, izindwani ze-aerospace turbine, nezingxenye zenjini yezimoto.

Izimila Zokwelapha

Ukwenza ama-alloys e-titanium afana ne-Ti-6Al-4V yokufakelwa kwe-hip noma idolo kuyinkimbinkimbi. Impahla iqinile, ayikuphathi kahle ukushisa, futhi idinga indawo ehlanzeke kakhulu ukuze igweme ukungcoliswa. Imishini eyomile ilungele ukweqa izinsalela zoketshezi, kodwa kunzima kumathuluzi. Okuzifakayo okuzithambisayo nge-MoS2 noma i-graphene coatings kusindisa ukuphila lapha. Inkampani ethile yemishini yezokwelapha eyenza izingxenye zesifazane yabona impilo yamathuluzi yeqa ngo-30% isebenzisa okufakwe i-CaF2-doped. I-lubricant yasika ukungqubuzana, yagcina amazinga okushisa ephansi, futhi yanikeza isiphetho esishelelayo, okubalulekile kuzimila ezidinga ukulingana kahle emzimbeni.

Ithiphu: Ngokufakwayo, hamba ngokufaka okuno-5–10% CaF2 futhi ugcine isivinini sokusika phakathi kuka-80–120 m/min ukuze ulinganisele ukuphila kwamathuluzi nekhwalithi yendawo. Hlola amathuluzi ngokuvamile ngesibonakhulu ukuze ubambe ukuguga kusenesikhathi, njengoba ngisho namaphutha amancane angaphazamisa ukubekezelela kokufakelwa.

I-Aerospace Turbine Blades

Ama-turbine blade ezinjinini ze-jet, ngokuvamile enziwa ngama-superalloy asuselwa ku-nickel njenge-Inconel 718, anzima ukuwenza ngoba aqinile futhi avame ukuqina nakakhulu ngesikhathi sokusika. Ukuwomisa amathuluzi ngaphandle kokuwashisa kuyinselele. Ukufakwa okunezindawo ezithungwe kanye nezinto zokugcoba ze-graphene kubonise imiphumela emihle. Kwesinye isikhathi, ukwenza ama-Inconel 718 ama-blade ane-graphene ahlanganiswe ne-graphene kusike ukugqokwa kwamathuluzi ngo-2.3% omncane kodwa obucayi futhi kuthuthukiswe ukushelela kwendawo ngaphezu kuka-20%. Lokhu bekusho ama-blade aqinile ahlala isikhathi eside ezinjinini.

Ithiphu: Sebenzisa okufakwayo okunamekwe nge-PVD kuma-turbine blades ukuze uthole ukumbozwa kwe-lubricant emimoyeni eyinkimbinkimbi. Namathela esivinini sokusika esingu-100–150 m/min namazinga okuphakela aphansi (0.1 mm/rev) ukuze ugweme ukushisa ngokweqile. Ngemva komshini, sebenzisa isibonakhulu se-electron yokuskena (SEM) ukuze ubone amaphethini okugqoka kusenesikhathi.

Izingxenye Zenjini Yezimoto

Ezingxenyeni zenjini yemoto njengama-crankshaft noma ama-camshaft, enziwe ngezinsimbi eziqinile njenge-AISI 4340, izitolo zidinga amathuluzi ahlala isikhathi eside futhi agcina izindleko ziphansi. Izithako ezizithambisayo nge-CaF2 noma i-MoS2 zisiza ngokunciphisa ukuguga nokwenza ama-chips aphatheke kalula ezimeni ezomile. Imboni eyodwa yezimoto esebenzisa okokufaka kwe-WC-10Co-5CaF2 yabona impilo yamathuluzi ikhuphuka ngo-25% umaukuphendukaInsimbi ye-AISI 1020, enama-chips abushelelezi kanye nesikhathi esincane sokuphumula kusukela ekushintsheni kwamathuluzi.

Ithiphu: Khetha okufakiwe okuno-10–12% we-cobalt wokuqina kanye ne-CaF2 ngokushelela. Gcina amapharamitha wokusika engashintshi—ake sithi, isivinini esingu-100 m/min nokujula okungu-0.5 mm kokusikwa— ukuze uthole imiphumela engaguquki. Buka i-chip buildup ukuze ugweme izindawo ezimaholoholo, ezingalimaza ingxenye yekhwalithi.

Ukwehlukaniswa Kwezindleko

Ukushintshela ekufakeni okuzithambisayo kubiza kakhulu kusengaphambili kodwa kuyakhokha ngokuhamba kwesikhathi. Nakhu ukuhlukaniswa:

Izindleko Zethuluzi: Lokhu kufakwa kusebenza ngamanani angu-20–30% kunejwayelekile. Ukufakwa kwe-WC-10Co-5CaF2 kungase kubize u-$15–$20 lilinye, uma liqhathaniswa no-$10–$12 ngokufaka okuvamile.
Izisetshenziswa: Ukwenza imishini eyomile ayidingi amasistimu oketshezi, ngakho-ke izindleko zokusetha ziphansi. Kodwa ukuthuthukela emishinini ye-CNC enembayo ukuze uthole imiphumela engcono kakhulu kungasebenzisa u-$50,000–$100,000.
Ithuluzi Life Savings: Lokhu kufakwa kuhlala isikhathi eside ngo-20–50%, kunciphisa ukushintshwa. Isitolo sokufakelwa kwezokwelapha songa u-$10,000 ngonyaka ngokwehlisa izinguquko zamathuluzi zisuka kweziyi-10 ziye kweziyisi-6 ngenyanga.
Ukonga Imvelo: Ukweqa uketshezi konga u-$5,000–$20,000 ngonyaka ekuthengeni, ekulondolozeni, nasekulahleni, kuye ngosayizi wesitolo.

Esitolo esisodwa somshini we-aerospace i-Inconel 718, okufakwayo okuvalwe nge-graphene kwehlise izindleko zizonke ngo-15% ngenxa yempilo ende yamathuluzi nokusetshenziswa kwamandla okuphansi. Imboni yezimoto yonge u-10% ezindlekweni zokukhiqiza ngokufaka i-CaF2, okubuyise izindleko zamathuluzi eziphakeme ezinyangeni eziyisithupha.

Ithiphu: Qalisa ukuhlaziywa kwezindleko zenzuzo, ukufaka izinto empilweni yamathuluzi, umthamo wokukhiqiza, nokonga uketshezi. Hlola ukufakwa esikalini esincane kuqala ukuze uqinisekise ukonga ngaphambi kokungena konke.

Izinyathelo Zokuqalisa

Nansi indlela yokuletha izinto zokuzithambisa esitolo sakho:

Khetha Faka Okulungile: Qondanisa okufakiwe nokwaziswa kwakho. Sebenzisa i-MoS2 noma i-graphene ye-titanium, i-CaF2 yezinsimbi. Khuluma nabahlinzeki mayelana nezingxube zangokwezifiso.
Setha Imishini: Linganisa imishini ye-CNC yomshini owomile. Khomba isivinini esingu-100–150 m/min, okuphakelayo okungu-0.1–0.2 mm/rev, nokushona kuka-0.5–1 mm.
Faka Amathuluzi: Faka okufakiwe ngokuvikelekile kuzibambi ukugwema ukudlidliza. Sebenzisa i-torque wrench ukuvimbela ukuqhekeka ekuqiniseni ngokweqile.
Yenza izivivinyo: Qala ngamaqoqo amancane ukuze ushayele izilungiselelo. Hlola ukuguga kwamathuluzi, ukuphela kwendawo, nokuma kwe-chip usebenzisa amathuluzi afana ne-SEM noma ama-profilometer.
Gada Bukhoma: Sebenzisa izinzwa ukuze ubuke amandla okusika namazinga okushisa ngesikhathi sokugijima. Lungisa izilungiselelo uma izinto zishisa kakhulu noma zigqoka ama-spikes.
Hlola Njalo: Hlola okufakiwe okunama-optical microscopes ukuze kuguge. Shintsha uma i-flank wear ifinyelela ku-0.3 mm ukuze ugcine ikhwalithi iphezulu.
Khuphula Kala: Uma ukuhlolwa kubukeka kukuhle, khiphela ekukhiqizweni okugcwele. Qeqesha iqembu lakho ngomshini owomile ukuze ugcine izinto zibushelelezi.

Ithiphu: Hlola emshinini owodwa kuqala, ulandelela amamethrikhi afana nempilo yamathuluzi nokuqedwa kwendawo. Sebenzisa idatha ukushuna kahle ngaphambi kokunwebela kweminye imishini.

Izinselele kanye Nokulungiswa

Izinto ezizigcobayo azilungile. Izindleko zangaphambili eziphezulu zingahlaba, kodwa ukonga empilweni yamathuluzi nasezindlekweni zoketshezi kuvame ukukukhokhela. Enye inkinga ukuthola inani lokuthambisa ngendlela efanele—okuningi kwenza ithuluzi libe buthaka, okuncane kakhulu akuligcobisi ngokwanele. Ucwaningo luphakamisa ukuthi u-5–10% wokuthambisa ufika endaweni emnandi. Imisebenzi enezinga lokushisa eliphezulu, njengokusika i-Inconel, ingehlisa isithunzi samanye ama-lubricant. Ukusebenzisa ezikwazi ukumelana nokushisa njenge-CaF2 noma ukuxuba izithambisi (isb, i-MoS2 ne-graphene) kuyasiza.

Ithiphu: Sebenza nochwepheshe bezinto ezibonakalayo ukuze uhlanganise izixube zokuthambisa zemisebenzi yakho. Qeqesha ama-opharetha njalo ukuphatha okufakiwe ngendlela efanele futhi bathole okuningi kukho.

Isiphetho

Izithako ezizithambisayo ze-tungsten carbide zishintsha umdlalo womshini owomile. Ngokushumeka izinto zokugcoba njenge-CaF2, i-MoS2, noma i-graphene, zinqamula ukungqubuzana, zithuthukisa impilo yamathuluzi, futhi zilethe izindawo ezingcono ezimbonini ezifana nezokwelapha, i-aerospace, nezimoto. Kusukela ekufakweni kwe-titanium kuya kuma-jet engine blade kuya kuma-crankshafts emoto, lawa mathuluzi afakazela ukubaluleka kwawo ezinhlelweni zokusebenza ezinzima. Izindleko zokuqala ziphezulu, kodwa ukonga impilo yamathuluzi ende, isikhathi esincane sokuphumula, futhi akukho uketshezi kuwenza ukubheja okuhlakaniphile. Ngohlelo olucacile—ukukhetha okufakiwe okufanele, ukumisa imishini, nokuhlola ngokucophelela—izitolo zingabhekana nezinselele futhi zibone izinzuzo zangempela. Njengoba ukukhiqiza kuphusha izindlela eziluhlaza, ezinembe kakhudlwana, lezi zinto ezifakwayo zisethelwe ukuba zibe yisisekelo ezitolo zesimanje.

Q&A

Q1: Yini eyenza i-self-lubricating tungsten carbide ifake ngaphandle kokujwayelekile?
I-A1: Zinezinto zokugcoba eziqinile ezakhelwe ngaphakathi njenge-CaF2 noma i-MoS2, ezinciphisa ukungqubuzana nokuguga ngesikhathi somshini owomile, aqede isidingo sokupholisa uketshezi.

Q2: Ingabe lezi zinto ezifakiwe zingaphatha noma iyiphi into?
A2: Zilungele izinto eziqinile njenge-titanium, ama-nickel alloys, nezinsimbi eziqinile. Khetha i-lubricant ngokusekelwe kokubalulekile ukuze uthole imiphumela engcono kakhulu.

Q3: Ngizithethelela kanjani izindleko ezengeziwe?
A3: Bheka izinzuzo zokuphila kwamathuluzi (20–50%), isikhathi esincane sokuphumula, nokonga kwezindleko zoketshezi. Ukuhlolwa kwezinga elincane kungabonisa ukuthi utshalomali luyakhokha yini esitolo sakho.

I-Q4: Yini engahamba kahle ngalokhu kufakwa?
I-A4: Ukuchotshozwa noma ukuguga kungenzeka, ikakhulukazi ngesivinini esikhulu. Lungiselela isivinini (100–150 m/min) futhi usebenzise izithambisi ezimelana nokushisa njenge-CaF2 ukuze unciphise izingozi.

I-Q5: Ngigcina kanjani ithrekhi yokusebenza kumshini owomile?
I-A5: Sebenzisa izinzwa ukuze uthole amandla esikhathi sangempela kanye nedatha yezinga lokushisa. Hlola amathuluzi okwenziwa ngemva komshini ngamakhroscope noma i-SEM ukuze ubambe ukuguga futhi ulungise izilungiselelo.

Izithenjwa

Ukuhlolwa kokusebenza kwethuluzi lokusika le-tungsten carbide-based self-lubricant cutting
Muthuraja, P., Senthilvelan, T.
Ijenali Yokukhiqiza Ubunjiniyela, 2016
Okutholiwe Okubalulekile: Ukufakwa kwe-WC-10Co-5CaF₂ kubonise ukuvinjelwa okuthuthukisiwe nokumelana nokugqokwa uma kuqhathaniswa ne-WC-10Co evamile.
Indlela yokwenza: Ukwenziwa kwe-powder metallurgy kanye nokuhlolwa kokusika.
Ingcaphuno: Muthuraja and Senthilvelan, 2016, pp. 1375-1394
https://www.semanticscholar.org/paper/Performance-evaluation-of-a-tungsten-carbide%E2%80%93based-Muthuraja-Senthilvelan/655246ce2f57b1e9e607c7343820b6ff30c65388
Imishini Eyomile Eqhubekayo Yensimbi Engagqwali Ngamathuluzi Okusika I-Tungsten Carbide Aphethwe yiMicrowave
Babe, IB, Gupta, K., Chaubey, SK
Imishini emincane, 2023
Okutholiwe Okubalulekile: Ukwelashwa kwe-microwave kuthuthukise ubulukhuni kanye nesakhiwo esincane, kunciphisa ukuguga kwamathuluzi nokuthuthukisa ukuqedwa kwendawo lapho kuphenduka okomile kwe-SS 316.
Indlela yokwenza: Idizayini ye-orthogonal ye-Taguchi L9 yohlelo lwe-orthogonal, ukwenza kahle kokusebenza okuningi, ukuhlaziywa kwe-SEM.
Ingcaphuno: Babe et al., 2023, pp. 1148
https://doi.org/10.3390/mi14061148
Ukuthuthukisa Ukusebenza Komshini Kokufakwa Kwethuluzi le-CNC Okumbozwe Ngezingubo Zekhabhoni Ezifana Nedayimane ngaphansi Kwendawo Eyomile Yokusika
Rana, R., Krishnia, L., Murtaza, Q., Walia, RS
Ijenali Yocwaningo Lobunjiniyela, 2021
Okutholakele Okubalulekile: Izembatho ze-DLC zandise ubulukhuni ngo-53%, ukumelana nokugqokwa okuthuthukisiwe kanye nokuqedwa kwengaphezulu ezimeni ezomile zomshini.
Indlela yokwenza: I-Thermal CVD coating isebenzisa i-bagasse yomoba, i-Raman spectroscopy, i-XRD, i-SEM, i-TOPSIS optimization.
Ingcaphuno: Rana et al., 2021, amakhasi 142-152
https://pdfs.semanticscholar.org/a610/52ce2a3de80013863263c6e88cb6c1b93699.pdf
- I-tungsten carbide
- Umshini owomile