Potentials of Ceramic Die Materials for Isothermal Forging Purposes of a Titanium Alloy

2014 ◽  
Vol 611-612 ◽  
pp. 202-211
Author(s):  
Bernd Arno Behrens ◽  
Mohammad Kazhai ◽  
Tobias Prüß
Keyword(s):  
High Performance ◽  
Tool Material ◽  
High Hardness ◽  
Work Load ◽  
Ceramic Tool ◽  
Isothermal Forging ◽  
Temperature Resistance ◽  
Die Materials ◽  
Technical Ceramics ◽  
Cutting Processes

The machining of titanium alloys is challenging in every aspect. In order to avoid waste material by cutting processes and to improve mechanical properties, forming processes offer many advantages but harbor also challenges. To face these challenges, especially techniques like isothermal forging are promising methods. Isothermal forging is an appropriate process for achieving a microstructure with excellent properties for high performance applications in aviation technology and turbine construction. One of the main challenges in this special process is the determination of a tool material with a high temperature resistance as well as a high resistance against the work load of forging processes. Given their high hardness, temperature resistance and wear resistance, technical ceramics feature properties classifying them as generally suitable for this application. This article deals with the complete design of an isothermal forging process with ceramic tool material for titanium forming. The material characterization of the forming material by flow curve determination is performed to receive data for FE analyses. Afterwards, a ceramic tool system for isothermal forging is designed and manufactured. The tests show that especially the brittleness of technical ceramics restricts their application as tool material for isothermal titanium forming. Additional investigations on isothermal forging using carbide metal as tool material show the benefit of isothermal titanium forging. The results of metallographic analyses are given.

scholarly journals Microstructure and Mechanical Properties of Spark Plasma Sintered Si3N4/WC Ceramic Tools

Materials ◽  
2019 ◽  
Vol 12 (11) ◽  
pp. 1868 ◽  
Author(s):  
Zhenhua Wang ◽  
Jiheng Jia ◽  
Liyan Cao ◽  
Ning Sun ◽  
Yulin Wang
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
High Performance ◽  
Bending Strength ◽  
Tool Material ◽  
Ceramic Materials ◽  
Ceramic Tool ◽  
Ceramic Tools ◽  
Abnormal Growth ◽  
High Temperature Mechanical Properties

Silicon nitride (Si3N4) based ceramic tools exhibit good machinability in cutting materials such as gray cast iron, ductile iron, malleable cast iron, and superalloys due to excellent high-temperature mechanical properties. In this paper, high-performance Si3N4-based ceramic tools containing tungsten carbide (WC) and cobalt (Co) were studied. Effects of the WC content and Co content on mechanical properties and a microstructure of Si3N4-based ceramic materials were analyzed. Results showed that Si3N4-based ceramic material containing 10 wt % WC and 1 wt % Co had the best comprehensive mechanical properties at a sintering temperature of 1650 °C and holding time of 6 min, achieving Vickers hardness, fracture toughness, and room temperature bending strength of 16.96 GPa, 7.26 MPa·m1/2, and 1132 MPa, respectively. The microstructure of Si3N4-based ceramic tool material is uniform without obvious abnormal growth. The Si3N4-based ceramic tool was mainly composed of α-Si3N4, β-Si3N4, and WC phases.

scholarly journals Real-Time Simulation of Force Parameters for Diagnostics of Ceramic Tool Condition During Milling of High-Hardness Steel Parts

2019 ◽  
Vol 224 ◽  
pp. 05004
Author(s):  
Marina A. Volosova ◽  
Vladimir D. Gurin ◽  
Anton E. Seleznev ◽  
Leonid E. Shvartsburg ◽  
Mariuch Jenek
Keyword(s):  
Real Time ◽  
High Speed ◽  
High Performance ◽  
Cutting Tools ◽  
Tool Material ◽  
High Hardness ◽  
Ceramic Materials ◽  
Hardened Steels ◽  
Time Simulation ◽  
Wide Range

Cutting ceramics is a high-performance tool material for high-speed machining of hard steels and alloys. Ceramic materials have high hardness and heat resistance in a wide range of temperatures, as well as chemical passivity in relation to most of the workpieces. However, the wider application of ceramic cutting tools is limited due to the low reliability - unpredictable fragile fracture of the cutting edge in different periods of operation. The study discusses mathematical simulations of force parameters in the milling of hardened steels using ceramic cutting tools. The simulation results were used to develop a system for the metalworking technological system state diagnostics. Mathematical software for calculations of the set of force parameters through computer simulations with taking into account the tool wear has been developed. The developed system allows calculating and graphically displaying a set of force parameters appearing during face milling of hardened steels in the real-time.

Mechanical properties, microstructure and crack healing ability of Al2O3/TiC/TiB2/h-BN@Al2O3 self-lubricating ceramic tool material

2021 ◽  
Vol 47 (10) ◽  
pp. 14551-14560
Author(s):  
Shuai Zhang ◽  
Guangchun Xiao ◽  
Zhaoqiang Chen ◽  
Lianggang Ji ◽  
Chonghai Xu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tool Material ◽  
Crack Healing ◽  
Ceramic Tool ◽  
Ceramic Tool Material

Effects of Nano-Al2O3 on the Mechanical Property and Microstructure of Nano-Micro Composite Self-Lubricating Ceramic Tool Material

2013 ◽  
Vol 770 ◽  
pp. 308-311 ◽  
Author(s):  
Ming Dong Yi ◽  
Chong Hai Xu ◽  
Zhao Qiang Chen ◽  
Guang Yong Wu
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Fracture Toughness ◽  
Flexural Strength ◽  
Tool Material ◽  
Ceramic Tool ◽  
Ceramic Tool Material ◽  
Composite Self ◽  
Microstructure And Mechanical Property ◽  
Grain Refinement Strengthening

A new nanomicro composite self-lubricating ceramic tool material was prepared with vacuum hot pressing technique. The effect of nanoAl2O3 powders on the microstructure and mechanical properties of nanomicro composite self-lubricating ceramic tool material was investigated. With the increase of nanoAl2O3 content, the hardness and fracture toughness first up then down. When the nanoAl2O3 content is 4 vol.%, the flexural strength, hardness and fracture toughness reaches 562 MPa, 8.46 MPa·m1/2 and 18.95 GPa, respectively. The microstructure and mechanical property of nanomicro composite self-lubricating ceramic tool material can be improved by the grain refinement strengthening of nanoAl2O3.

Influences of Sintering Process on the Microstructure and Mechanical Behavior of ZrO2 Nano-Composite Ceramic Tool and Die Material

2010 ◽  
Vol 154-155 ◽  
pp. 1356-1360 ◽  
Author(s):  
Ming Dong Yi ◽  
Chong Hai Xu ◽  
Jing Jie Zhang ◽  
Zhen Yu Jiang
Keyword(s):  
Mechanical Properties ◽  
Ceramic Material ◽  
Composite Ceramic ◽  
Sintering Process ◽  
Ceramic Tool ◽  
Nano Composite ◽  
Pure Zro2 ◽  
Die Materials ◽  
Die Material ◽  
Composite Ceramic Material

A new ZrO2 nano-composite ceramic tool and die material was prepared with vacuum hot pressing technique. The effects of sintering parameters on the nano-composite ceramic tool and die materials were studied. The results indicated that the mechanical properties of ZrO2 nano-composite ceramic tool and die material with the additions of TiB2 and Al2O3 are higher than that of the pure ZrO2 ceramic material. Sintering at 1100 for 120min could improve the density and mechanical properties of ZrO2 nano-composite ceramic material. The flexural strength, fracture toughness and hardness with the optimum sintering parameters can reach 878MPa, 9.54MPa•m1/2 and 13.48GPa, respectively, obviously higher than that with non-optimum sintering parameters.

Microstructure Simulation and Toughening Mechanism of Ceramic Tool Material

2011 ◽  
Vol 335-336 ◽  
pp. 688-694
Author(s):  
Xiao Hui Zhu ◽  
Chuan Zhen Huang ◽  
Han Lian Liu ◽  
Bin Zou ◽  
Hong Tao Zhu
Keyword(s):  
Mechanical Properties ◽  
Single Phase ◽  
Three Dimensional ◽  
Tool Material ◽  
Ceramic Tool ◽  
Toughening Mechanism ◽  
C Language ◽  
Finite Element Software ◽  
Microstructure Simulation ◽  
Ceramic Tool Material

Based on the microstructure results of Monte Carlo simulation, a three-dimensional grid model is built up, and imported into the finite element software with C++ language to analyze the mechanical properties of ceramic tool material. The stress field and residual stress of single-phase and multiphase ceramics have been analyzed by the computer simulation technology.

Prozessüberwachung beim ultraschallunterstützten Schleifen*/Influence of the tool-workpiece contact on the ultrasonic amplitudes in the grinding process

2018 ◽  
Vol 108 (07-08) ◽  
pp. 513-518
Author(s):  
J. Bruckhoff ◽  
E. Uhlmann
Keyword(s):  
High Hardness ◽  
Grinding Process ◽  
Process Measurement ◽  
Hard Materials ◽  
Grinding Processes ◽  
Technical Ceramics

Hinsichtlich Zähigkeit verbesserte technische Keramiken führen in Kombination mit der materialspezifischen hohen Härte dieser sprödharten Werkstoffe zu Herausforderungen bei der Bearbeitung. Das präzise sowie wirtschaftliche Bearbeiten geschieht daher vorwiegend mit Schleifverfahren. Die Ultraschallunterstützung kann die Produktivität von Schleifprozessen erhöhen. In-Prozess-Messungen der Ultraschallamplitude sollen Aufschluss über die Wechselwirkungen von Werkstück und Werkzeug geben.   Due to improved toughness and material-specific high hardness of technical ceramics, the machining of these brittle-hard materials is challenging. Therefore, precise and economical processing is mainly done by grinding. Ultrasonic support can increase the productivity of grinding processes. In-process measurement of ultrasonic amplitudes provides information about the interaction between the workpiece and the tool.

scholarly journals Modification of the Johnson–Cook Material Model for Improved Simulation of Hard Milling High-Performance Steel Components

2021 ◽  
Vol 2 (3) ◽  
pp. 571-580
Author(s):  
Andrey Vovk ◽  
Amin Pourkaveh Dehkordi ◽  
Rainer Glüge ◽  
Bernhard Karpuschewski ◽  
Jens Sölter
Keyword(s):  
High Performance ◽  
Kinematic Hardening ◽  
Material Model ◽  
Detailed Knowledge ◽  
Hard Milling ◽  
Bending Tests ◽  
Finite Element Software ◽  
Steel Material ◽  
Finish Cutting ◽  
Cutting Processes

Understanding the effect of thermomechanical loads during finish cutting processes, in our case hard milling, on the surface integrity of the workpiece is crucial for the creation of defined quality characteristics of high-performance components. Compared to computationally generated modifications by simulation, the measurement-based determination of material modifications can only be carried out selectively and on a point-by-point basis. In practice, however, detailed knowledge of the changes in material properties at arbitrary points of the high-performance component is of great interest. In this paper, a modification of the well-known Johnson–Cook material model using the finite element software Abaqus is presented. Special attention was paid to the kinematic hardening behavior of the used steel material. Cyclic loads are relevant for the chip formation simulation because, during milling, after each cut, the material under the surface is loaded plastically several times and not necessarily in the same direction. Therefore, in analogy, multiple bending was investigated on samples made of 42CrMo4. A pronounced Bauschinger effect was observed in the bending tests. An adaptation of the material model to the results of the bending tests was only possible to a limited extent without kinematic hardening, which is why the Johnson–Cook model was supplemented by the Armstrong–Frederick hardening approach. The modified Johnson–Cook–Armstrong–Frederick material model was developed for practical use as a VUMAT and verified by bending tests for simulation use.

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