Study On The Development And Performance Of Novel Ceramic Tools Based On Al₂O₃

Along with the development of nuclear power industry and the major needs of state, "the Key Scientific Problems of Manufacturing Nuclear Main Pump" was classified as the National 973 Plan Project. Undefiled & integrated manufacturing of key parts of nuclear main pump is one core technology of manufacturing nuclear main pump. The exploration and investigation of undefiled & integrated manufacturing process have important theoretical values and far-reaching significance. This article is on the basis of summarizing domestic and international undefiled & integrated manufacturing technology of nuclear main pump. The conflict is viewed between its high undefiled & integrated manufacturing requirements and failing to meet machining demand using current cutting tools. To obtain high undefiled & integrated manufacturing surface, an experimental plan is proposed through which undefiled & integrated machining for key parts of nuclear main pump can be achieved employing novel ceramic cutting tools based on Al2O3. Investigation of ceramic cutting tools, undefiled cutting experiment, integrated cutting experiment, wear resistance and mechanism research, etc. are carried out.Firstly, according to the undefiled & integrated manufacturing requirements of key parts of nuclear main pump, this paper developed two kinds of novel ceramic cutting tools based on Al2O3, including tools' ingredients, press-forming and sintering process, mechanical processing, etc; after tools were prepared, performance parameters were tested.Secondly, the novel ceramic cutting tools were adopted in dry-cutting SUS304 experiment of analyzing surface cleanliness, dry-cutting SUS304 experiment of analyzing surface integrality. A comparison was conducted between the novel and traditional hard alloy cutting tools (YG8) and Ti(C,N) based on alumina. Undefiled aspect (element distribution, seepage condition), integrated aspect (roughness, surface morphology) were researched and analyzed. The experimental results showed that the E novel ceramic cutting tool exhibited better property of undefiled aspect and integrated aspect of machining surface compared with traditional ones. Finally, certain feasibility of this experiment scheme is proved.Furthermore, preliminary research on the wear resistance of novel ceramic cutting tools was carried out. A comparison was conducted between the novel and traditional hard alloy cutting tools (YG8) on tool point wear, chip morphology, etc. The experimental results showed that when high-speed cutting SUS304 material in the condition of smaller cutting depth ap and feeding speed f,wear resistance of scheme E ceramic cutting tools was similar with that of carbide cutting tools and a better wear resistance of scheme A cutting tools was confirmed. As cutting depth ap increased to a certain limit, the novel cutting tools exhibited poorer property of wear resistance compared with traditional hard alloy cutting tools because of breaking blade, brittle fracture etc. caused by poorer toughness of ceramic cutting tools.Finally, wear mechanism of the novel ceramic cutting tools based on Al2O3 in dry-cutting SUS304 material was viewed in this paper. The experimental results showed that in the condition of dry-cutting, wear mechanism property were similar with each other between two kinds of novel ceramic cutting tools and traditional cutting tools, e.g. oxidation wear and adhesive wear, fatigue fracture, particle attrition, etc.