Ceramic cutting tool with temperature sensor, pressure sensor and cutting function, and preparation method and application thereof

Abstract

The application discloses a ceramic cutter with temperature sensing, pressure sensing and cutting functions and a preparation method and application thereof. The ceramic cutter is of a layered structure and comprises a ceramic base layer and a pyroelectric material layer attached to one side of the ceramic base layer. The functional material of the pyroelectric material layer is selected from one or a combination of PZT, PLZT or ZnO. The base material of the ceramic base layer is selected from one or a combination of Al2O3, Si3N4 or CBN. The doped phase of the pyroelectric material layer is selected from one or a combination of CeO2 and La2O3. The ceramic cutter integrates the cutting temperature measurement function, the cutting force measurement function and high mechanical properties, so that the cutting force and the cutting temperature can be simultaneously detected under the premise of meeting the cutting performance requirements, that is, the cutting temperature and the cutting force can be measured without additional temperature and force sensors during cutting, and the ceramic cutter has the advantages of simple structure, small volume, high hardness, high bending strength and high fracture toughness, convenient installation and the like.

Description

Technical Field

[0001] This invention belongs to the field of machining technology, and relates to milling and cutting processes, specifically to a ceramic cutting tool with temperature sensing, pressure sensing and cutting functions, its preparation method and application. Background Technology

[0002] The statements herein provide only background information in relation to this invention and do not necessarily constitute prior art.

[0003] Cutting temperature and cutting force are important sources of information reflecting the state of machining (such as milling and cutting), and are closely related to tool cutting parameters, cutting conditions, tool condition, and workpiece surface finish. By monitoring cutting temperature and cutting force during the cutting process, tool wear, tool life, and workpiece surface quality can be predicted, thereby optimizing machining process parameters (such as tool speed) to improve machining quality and efficiency.

[0004] Currently, the most mature and widely used cutting force detection technologies are mainly resistance strain gauge and piezoelectric types. Cutting temperature is generally measured using contact and non-contact methods, which cannot simultaneously measure cutting force and cutting temperature. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions, as well as its preparation method and application. This ceramic cutting tool integrates cutting temperature measurement, cutting force measurement, and high mechanical properties into one unit. It enables simultaneous detection of cutting force and cutting temperature while meeting cutting performance requirements. In other words, no additional temperature or force sensors are needed during cutting to measure cutting temperature and cutting force. It offers advantages such as simple structure, small size, high hardness, high bending strength and fracture toughness, and convenient installation.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0007] In a first aspect, the present invention provides a ceramic cutting tool with temperature sensing, pressure sensing and cutting functions, which has a layered structure, including a ceramic matrix layer and a pyroelectric material layer attached to at least one side of the ceramic matrix layer; the functional material of the pyroelectric material layer is selected from one or a combination of PZT, PLZT or ZnO; the matrix material of the ceramic matrix layer is selected from one or a combination of Al2O3, Si3N4 or CBN; and the doped phase of the pyroelectric material layer is selected from one or a combination of CeO2 and La2O3.

[0008] This invention enables ceramic cutting tools to exhibit both piezoelectric and pyroelectric effects by doping a pyroelectric functional phase into a ceramic matrix. When a gradient ceramic cutting tool with piezoelectric and pyroelectric effects cuts a part, it can convert cutting force and temperature signals into electrical signals. The electrical signals generated by pressure and temperature are distinguished by a signal separator, and the processed electrical signals are amplified by a signal amplifier. This allows for real-time measurement of cutting temperature and cutting force in the cutting area, and monitoring of the working status of the gradient ceramic cutting tool.

[0009] Meanwhile, by selecting ceramic matrix materials and pyroelectric materials, the present invention improves the mechanical properties of ceramic cutting tools through the mutual coordination of various materials and components, thereby enabling them to not only have temperature and pressure sensing properties, but also ensure the cutting performance of ceramic cutting tools.

[0010] In some embodiments, the mass percentage of the doped phase in the pyroelectric material layer is 3%-10%. The doped phase is used to improve the mechanical properties of the cutting tool.

[0011] Preferably, the mass percentage of PZT in the pyroelectric material layer is 40%-60%, and the mass percentage of PLZT is 0-20%.

[0012] In some embodiments, the total thickness of the pyroelectric material layer accounts for 25%-60% of the total thickness of the ceramic cutting tool. This layer has a pyroelectric effect, which can convert cutting temperature signals, cutting pressure signals, and cutting charge signals into charge signals.

[0013] In some embodiments, the ceramic matrix layer further includes a binder and / or a reinforcing phase. This layer possesses high hardness, high wear resistance, high flexural strength, and high fracture toughness, enabling it to cut metals.

[0014] Preferably, the binder is selected from one or a combination of Mo, Ni, Co, W or Cr.

[0015] Preferably, the reinforcing phase is selected from one or a combination of TiC, WC, SiC, MgO, Cr2O3, TiO2, or ZrO2. The role of the reinforcing phase is to further increase the mechanical properties of the ceramic cutting tool.

[0016] Preferably, in the ceramic matrix layer, the mass percentage of the binder is 1%-5%, and the mass percentage of the reinforcing phase is 30%-45%.

[0017] In some embodiments, an adhesive layer is included between the ceramic substrate layer and the pyroelectric material layer. The adhesive layer is made from one or a combination of Al2O3, Si3N4, CBN, Ni, Co, or MgO. The adhesive layer can improve the bond strength between the ceramic substrate layer and the pyroelectric material layer.

[0018] Preferably, the total thickness of the adhesive layer accounts for 2%-15% of the total thickness of the ceramic cutting tool.

[0019] In some embodiments, the total thickness of the ceramic matrix layer accounts for 50%-70% of the total thickness of the ceramic cutting tool. This ensures the mechanical properties of the ceramic cutting tool, as well as its temperature and force measurement capabilities.

[0020] In some embodiments, the pyroelectric material layers are arranged in layers.

[0021] Preferably, the ceramic matrix layer is arranged in layers.

[0022] Secondly, the present invention provides a method for preparing the ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions, comprising the following steps:

[0023] Each raw material is made into powder, and the powders are mixed in proportion layer by layer. The mixture is then filled and compacted layer by layer, and vacuum hot-pressed and sintered to obtain the final product.

[0024] First, the material is made into powder, which facilitates the mixing of the various components in the material, increases the synergistic effect between the components, and improves the mechanical properties of ceramic cutting tools. Vacuum hot pressing sintering not only ensures that the sintered material is denser, further improving the mechanical properties of ceramic cutting tools, but also avoids graphite oxidation and increases the temperature sensing performance of ceramic cutting tools.

[0025] The raw materials are prepared into powder by ball milling.

[0026] In some embodiments, the compaction pressure is 4-6 MPa.

[0027] In some embodiments, during vacuum hot pressing sintering, the sintering temperature is 1000-1500℃, the sintering time is 50-60min, and the sintering pressure is 30-35MPa.

[0028] Thirdly, the present invention provides the application of the ceramic cutting tool with temperature sensing, pressure sensing and cutting functions in cutting or milling processes.

[0029] Fourthly, the present invention provides a cutting machine tool, wherein the cutting tool is the ceramic tool, and the pyroelectric layers on both sides of the ceramic tool are connected to a signal distinguishing instrument and a signal amplifier respectively through two wires.

[0030] When ceramic cutting tools cut a workpiece, the cutting temperature and force cause distortion of the pyroelectric material's crystal lattice, leading to charge overflow. A charge signal distinguisher differentiates pressure and temperature signals, which are then amplified by a charge amplifier and wirelessly transmitted to a cutting temperature and force monitoring system via a signal transmitter. This enables real-time measurement of cutting temperature and force. Based on the real-time measured cutting temperature and force, machining parameters such as tool rotation speed are adjusted, thereby improving machining quality and efficiency.

[0031] The beneficial effects achieved by one or more embodiments of the present invention described above are as follows:

[0032] This invention achieves the cutting function of ceramic cutting tools and real-time measurement of cutting pressure and temperature during the cutting process by selecting pressure and temperature-sensitive materials and designing the tool structure. The tool is both a sensor and a cutting tool, and it is simple to install, has no impact on the machine tool, and can be used without changing the existing machine tool structure and system. Attached Figure Description

[0033] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0034] Figure 1 This is a schematic diagram illustrating the cutting temperature measurement and tool condition monitoring principle of a ceramic cutting tool that integrates temperature sensing, pressure sensing, and cutting functions in an embodiment of the present invention.

[0035] Figure 2 This is a schematic diagram of the integrated ceramic cutting tool for temperature sensing, pressure sensing, and cutting functions according to Embodiment 1 of the present invention.

[0036] Figure 3 This is a schematic diagram of the integrated ceramic cutting tool for temperature sensing, pressure sensing, and cutting functions according to Embodiment 2 of the present invention.

[0037] Figure 4 This is a schematic diagram of the integrated ceramic cutting tool for temperature sensing, pressure sensing, and cutting functions in Embodiment 3 of the present invention.

[0038] Figure 5 This is a schematic diagram of the integrated ceramic cutting tool for temperature sensing, pressure sensing, and cutting functions in Embodiment 4 of the present invention.

[0039] Among them, 1. ceramic cutting tool integrating temperature sensing, pressure sensing and cutting function; 2. set screw; 3. tool holder; 4. cutting point; 5. compensation wire; 6. signal amplifier; 7. temperature measuring instrument and pressure measuring instrument. Detailed Implementation

[0040] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0041] In the following embodiments, the powders of each layer are mixed and ball-milled using anhydrous ethanol as the medium. After vacuum drying and sieving, the powder is layered and compacted, followed by vacuum hot pressing sintering to produce a ceramic tool material integrating temperature sensing, pressure sensing, and cutting functions. This integrated ceramic tool material is then cut and polished to produce a ceramic tool integrating temperature sensing, pressure sensing, and cutting functions. The principle of measuring cutting temperature and cutting force and monitoring tool condition is as follows: Figure 1 As shown.

[0042] A ceramic cutting tool 1, integrating temperature sensing, pressure sensing, and cutting functions, is fixed to a tool holder 3 by a set screw 2. When this integrated ceramic cutting tool 1 cuts the workpiece material, the cutting temperature at the cutting point 4 causes a current to flow through the tool, generating piezoelectric and pyroelectric effects. The cutting temperature and pressure are then connected to a signal amplifier 6 via a compensating wire 5, and finally to a temperature and pressure measuring instrument 7, enabling real-time measurement of the cutting temperature and pressure.

[0043] Example 1

[0044] A ceramic tool structure integrating temperature sensing, pressure sensing, and cutting functions, such as... Figure 2 As shown, it has a double-layer structure. The first layer is a pyroelectric material such as PZT and PLZT, which accounts for 40% of the total thickness of the tool. The second layer is an Al2O3 or Si3N4-based ceramic material, which accounts for 60% of the total thickness of the tool.

[0045] In this embodiment, the powder materials required to prepare the ceramic cutting tool integrating temperature sensing, pressure sensing and cutting functions are shown in Table 1, which gives the weight ratio (wt.%) of powder components A1 (first layer) and A2 (second layer).

[0046] Table 1. Powder component weight ratio (wt.%)

[0047]

[0048] The powder materials were separately loaded into ball mill jars, using ZrO2 balls as grinding balls and anhydrous ethanol as the grinding medium, and milled for 48 hours. The milled suspension was then dried in a vacuum drying oven, passed through a 160-mesh sieve, and sealed for later use. Subsequently, the powder was uniformly mixed according to the requirements of each layer of the ceramic cutting tool, and by controlling the thickness of each layer, the powder material was filled into the mold layer by layer in the order A1 / A2. Each layer of powder needed to be leveled and compacted until the powder was completely filled. The powder was pre-compacted at 5 MPa, and then placed in a vacuum hot-pressing sintering furnace for hot-pressing sintering at a sintering temperature of 1200℃, a sintering time of 50 min, and a sintering pressure of 30 MPa.

[0049] After sintering, a high-density ceramic blank is obtained. After cutting and polishing, it is made into a ceramic cutting tool with a three-layer structure that integrates temperature sensing, pressure sensing, and cutting functions. By installing the cutting tool and temperature and force measuring instruments onto the tool holder, real-time measurement of cutting temperature and cutting force can be achieved.

[0050] Example 2

[0051] A ceramic tool structure integrating temperature sensing, pressure sensing, and cutting functions, such as... Figure 3 As shown, it has a three-layer structure. The first layer is a pyroelectric material such as PZT and PLZT, and its thickness is 30% of the total thickness of the tool. The second layer is a mixed layer of various materials such as Al2O3, Si3N4, CBN, Ni, Co, and MgO, and its thickness is 20% of the total thickness of the tool. The third layer is an Al2O3 or Si3N4 based ceramic material, and its thickness accounts for 50% of the total thickness of the tool.

[0052] In this embodiment, the powder materials required to prepare the ceramic cutting tool integrating temperature sensing, pressure sensing and cutting functions are shown in Table 2, which gives the weight ratio (wt.%) of powder components B1 (first layer), B2 (second layer) and B3 (third layer).

[0053] Table 2. Powder component weight ratio (wt.%)

[0054]

[0055] The powdered materials were separately loaded into ball mill jars, using ZrO2 balls as grinding balls and anhydrous ethanol as the grinding medium, and milled for 48 hours. After milling, the suspension was dried in a vacuum drying oven, passed through a 160-mesh sieve, and sealed for later use. Subsequently, the powder was uniformly mixed according to the material requirements of each layer of the ceramic cutting tool. By controlling the thickness of each layer, the powder was filled into the mold layer by layer in the order of B1 / B2 / B3. Each layer of powder needed to be leveled and compacted until the powder was completely filled. The powder was pre-compacted at 5 MPa, and then placed in a vacuum hot-pressing sintering furnace for hot-pressing sintering at 1200℃ for 50 minutes and 30 MPa. After sintering, a high-density ceramic blank was obtained. After cutting and polishing, a ceramic cutting tool with a three-layer structure integrating temperature sensing, pressure sensing, and cutting functions was manufactured. By installing the cutting tool and temperature and force measuring instruments onto the tool holder, real-time measurement of cutting temperature and cutting force can be achieved.

[0056] Example 3

[0057] A ceramic tool structure integrating temperature sensing, pressure sensing, and cutting functions, such as... Figure 4 As shown, it has a three-layer structure. The first and third layers are pyroelectric materials such as PZT and PLZT, and their thickness is 40% of the total thickness of the tool. The second layer is an Al2O3 or Si3N4 based ceramic material, and its thickness accounts for 60% of the total thickness of the tool.

[0058] In this embodiment, the powder materials required to prepare the ceramic cutting tool integrating temperature sensing, pressure sensing and cutting functions are shown in Table 1, which gives the weight ratio (wt.%) of C1 (first layer, third layer) and C2 (second layer) powder components.

[0059] Table 3. Powder component weight ratio (wt.%)

[0060]

[0061] The powder materials were separately loaded into ball mill jars, using ZrO2 balls as grinding balls and anhydrous ethanol as the grinding medium, and milled for 48 hours. The milled suspension was then dried in a vacuum drying oven, passed through a 160-mesh sieve, and sealed for later use. Subsequently, the powder was uniformly mixed according to the requirements of each layer of the ceramic cutting tool, and by controlling the thickness of each layer, the powder material was filled into the mold layer by layer in the order of C1 / C2 / C1. Each layer of powder needed to be leveled and compacted until the powder was completely filled. The powder was pre-compacted at 5 MPa, and then placed in a vacuum hot-pressing sintering furnace for hot-pressing sintering at 1200℃ for 50 minutes and a sintering pressure of 30 MPa.

[0062] After sintering, a high-density ceramic blank is obtained. After cutting and polishing, it is made into a ceramic cutting tool with a three-layer structure that integrates temperature sensing, pressure sensing, and cutting functions. By installing the cutting tool and temperature and force measuring instruments onto the tool holder, real-time measurement of cutting temperature and cutting force can be achieved.

[0063] Example 4

[0064] A ceramic tool structure integrating temperature sensing, pressure sensing, and cutting functions, such as... Figure 5 As shown, the tool has a five-layer structure. The first and fifth layers are pyroelectric materials such as PZT and PLZT, with a thickness of 30% of the total tool thickness. The third layer is an Al2O3 or Si3N4-based ceramic material, with a thickness of 50% of the total tool thickness. The second and fourth layers are mixed layers of various materials such as Al2O3, Si3N4, CBN, Ni, Co, and MgO, with a thickness of 20% of the total tool thickness.

[0065] In this embodiment, the powder materials required to prepare the ceramic cutting tool integrating temperature sensing, pressure sensing and cutting functions are shown in Table 2, which gives the weight ratio (wt.%) of powder components D1 (first layer, fifth layer), D2 (second layer and fourth layer), and D3 (third layer).

[0066] Table 4. Powder component weight ratio (wt.%)

[0067]

[0068] The powdered materials were separately loaded into ball mill jars, using ZrO2 balls as grinding balls and anhydrous ethanol as the grinding medium, and milled for 48 hours. After milling, the suspension was dried in a vacuum drying oven, passed through a 160-mesh sieve, and sealed for later use. Subsequently, the powder was uniformly mixed according to the material requirements of each layer of the ceramic cutting tool. By controlling the thickness of each layer, the powder was filled into the mold layer by layer in the order D1 / D2 / D3 / D2 / D1, with each layer being leveled and compacted until all layers were filled. The powder was pre-compacted at 5 MPa, and then placed in a vacuum hot-pressing sintering furnace for hot-pressing sintering at 1200℃ for 50 minutes and 30 MPa. After sintering, a high-density ceramic blank was obtained, which was then cut and polished to produce a ceramic cutting tool with a five-layer structure integrating temperature sensing, pressure sensing, and cutting functions. By installing the cutting tool and temperature and force measuring instruments onto the tool holder, real-time measurement of cutting temperature and cutting force can be achieved.

[0069] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions, characterized in that: It has a layered structure, including a ceramic matrix layer and a pyroelectric material layer attached to at least one side of the ceramic matrix layer; The functional material of the pyroelectric material layer is selected from one or a combination of PZT, PLZT or ZnO; The matrix material of the ceramic matrix layer is selected from one or a combination of Al2O3, Si3N4 or CBN; The doped phase of the pyroelectric material layer is selected from one or a combination of CeO2, La2O3.

2. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 1, characterized in that: The mass percentage of the doped phase in the pyroelectric material layer is 3%-10%.

3. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 1, characterized in that: When the functional material of the pyroelectric material layer is a combination of PZT and PLZT, the mass percentage of PZT in the pyroelectric material layer is 40%-60%, and the mass percentage of PLZT is 0-20%.

4. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 1, characterized in that: The total thickness of the pyroelectric material layer accounts for 25%-60% of the total thickness of the ceramic cutting tool.

5. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 1, characterized in that: The ceramic matrix layer also includes binders and / or reinforcing phases.

6. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 5, characterized in that: The binder is selected from one or a combination of Mo, Ni, Co, W or Cr.

7. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 5, characterized in that: The reinforcing phase is selected from one or a combination of TiC, WC, SiC, MgO, Cr2O3, TiO2 or ZrO2.

8. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 5, characterized in that: When the ceramic matrix layer is a combination of binder and reinforcing phase, the mass percentage of binder is 1%-5% and the mass percentage of reinforcing phase is 30%-45%.

9. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 1, characterized in that: An adhesive layer is included between the ceramic substrate layer and the pyroelectric material layer. The raw material of the adhesive layer is selected from one or a combination of Al2O3, Si3N4, CBN, Ni, Co or MgO.

10. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 9, characterized in that: The total thickness of the bonding layer accounts for 2%-15% of the total thickness of the ceramic cutting tool.

11. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 9, characterized in that: The total thickness of the ceramic matrix layer accounts for 50%-70% of the total thickness of the ceramic cutting tool.

12. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 1, characterized in that: The pyroelectric material layers are arranged in layers.

13. The ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 1, characterized in that: The ceramic matrix layer is arranged in layers.

14. A method for preparing a ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions as described in any one of claims 1-13, characterized in that: Includes the following steps: Each raw material is made into powder, and the powders are mixed in proportion layer by layer. The mixture is then filled and compacted layer by layer, and vacuum hot-pressed and sintered to obtain the final product.

15. The method for preparing a ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 14, characterized in that: The compaction pressure is 4-6 MPa.

16. The method for preparing a ceramic cutting tool with temperature sensing, pressure sensing, and cutting functions according to claim 14, characterized in that: During vacuum hot pressing sintering, the sintering temperature is 1000-1500℃, the sintering time is 50-60min, and the sintering pressure is 30-35MPa.

17. The application of the ceramic cutting tool with temperature sensing, pressure sensing and cutting functions as described in any one of claims 1-13 in cutting processes.

18. A cutting machine tool, characterized in that: The cutting tool is a ceramic tool as described in any one of claims 1-6. A pyroelectric material layer is provided on both sides of the ceramic tool. The pyroelectric material layer on both sides of the ceramic tool is connected to a signal distinguishing instrument and a temperature and pressure measuring instrument respectively through two wires.

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