Wear Mechanisms of Hard-Brittle Material Tools in High-Speed Machining of Powder Metallurgy Material

A series of experiments was conducted in high speed machining of powder metallurgy material with PCBN tools. The main tool wear mechanisms were discussed by observing tool wear morphology utilizing scanning electron microscopy (SEM) and detecting the element distribution of the worn tool surface using energy dispersive spectroscopy (EDS).The experimental results indicate that fragile breakage occurred before it reached its blunt standard in high-speed machining of powder metallurgy material with PCBN tools,and the tools wear mechanisms are synergistic interaction among mechanical wear,binder wear and chemical wear.

Design of Ultrasonic Compaction Tool for Powder Metallurgy

The current study is presented into the investigation of the application of ultrasonic vibration on the lower punch during compaction process of powder metallurgy material. The lower punch is specifically designed of ultrasonic horn which has been tuned at frequency of 20 kHz and vibrates in longitudinal mode. Finite Element modeling was used to assist the design process of the lower punch or horn. The horn was fabricated using high grade aluminium alloy and mounted onto the ultrasonic system test rig and subsequently tested prior the experimental process begins. Various static and ultrasonic compaction procedures have been carried out to confirm the capability of the tool to operate. The compaction force was reduced significantly at the onset of ultrasonic vibration applied compared to without ultrasonic.

ULTRASONIC FATIGUE BEHAVIOR OF A Fe-BASED WARM-COMPACTED POWDER METALLURGY MATERIAL

Fe -2 Cu -2 Ni -1 Mo -1 C powder metallurgy material was fabricated by die-wall lubricated warm compaction and ultrasonic fatigue test was carried out for as-sintered and heat treatment samples. Material fatigue strength reaches 249 MPa under axial fatigue testing. The sintered material consists of acicular martensite, pearlite, bainite and retained austenite. Tempered martensite is the major phases after heat-treatment. Cleavage plane and dimples is mixed fracture for sample after axial fatigue test. Mechanical properties of after heat treatment materials are improved and fatigue strength reaches 382 MPa under 107 cycles in bending ultrasonic fatigue test. The fatigue strength increases significantly in high cycles range.

ANCORLOY HP-1

Ancorloy HP-1 is a press-ready, engineered binder-treated premixed ferrous powder metallurgy material designed for enhanced as-sintered mechanical properties. This datasheet provides information on composition, physical properties, hardness, and tensile properties as well as fracture toughness. It also includes information on powder metal forms. Filing Code: SA-676. Producer or source: Hoeganaes Corporation.