Anti-abrasion sliding block module based on gradient material and micro-texture design and manufacturing method of anti-abrasion sliding block module

Abstract

The invention discloses an anti-wear sliding block module and a manufacturing method thereof, and the problems of poor interface bonding force, lubrication failure and stress concentration are systematically solved through gradient material composite structure (silicon nitride / WC-10Co / aluminum alloy), scaly micro-texture lubrication design and biarc transition shot peening strengthening. The manufacturing process integrates laser cladding synchronous deposition, femtosecond laser processing and magnetron sputtering coating technologies, and efficient and precise manufacturing is achieved. Experiments show that the wear life of the module is prolonged by 3 times, the friction coefficient is reduced to 0.08, and the industrial application value is remarkable.

Description

Technical Field

[0001] The present invention relates to the technical field of precision machinery manufacturing, and particularly relates to an anti-wear slider module based on gradient material and micro-texture design and a manufacturing method thereof. Background Art

[0002] In the field of precision mechanical transmission, as the core component of a linear motion system, the wear resistance, structural reliability, and service life of a slider module directly affect the overall performance of the equipment. However, the following technical defects still exist in the existing slider modules during actual applications:

[0003] 1. Insufficient interfacial bonding strength of materials

[0004] Traditional slider modules mostly adopt single materials or simple laminated structures (such as spraying ceramic coatings on the surface of an aluminum alloy substrate). Due to the significant differences in the thermal expansion coefficients of different materials, stress concentration is likely to occur at the interface under frequent movement and temperature changes, resulting in coating peeling or substrate cracking. In addition, traditional bonding or mechanical fixing processes are difficult to achieve high-strength bonding between layers, further reducing the overall life of the module.

[0005] 2. Lubrication failure and friction fluctuation

[0006] The existing micro-texture designs (such as linear grooves, circular pits) have limited oil storage capacity, and lubricants are easily lost during movement. It is difficult to maintain a stable lubricating film under long-term high-load working conditions. Especially in application scenarios with frequent starts and stops, the friction coefficient fluctuates significantly, accelerating wear and causing a decline in motion accuracy.

[0007] 3. Stress concentration caused by geometric structure

[0008] In the module, stress concentration is easily generated at the right-angle transition area due to geometric mutations, becoming the initiation point of fatigue cracks. Although the conventional arc transition design can partially relieve stress, the selection of its parameters lacks targeted optimization and cannot effectively inhibit crack propagation, resulting in early failure of the module.

[0009] 4. Complexity of manufacturing process and cost limitation

[0010] Traditional gradient materials need to be realized through multiple depositions, heat treatments, and precision machining. The process steps are cumbersome and the efficiency is low. In addition, the processing of high-precision micro-textures relies on complex equipment and is costly, restricting its large-scale application.

[0011] The above problems do not exist in isolation but are interrelated and exacerbate each other:

[0012] 1. Process complexity and interfacial defects: The interfacial contamination and thermal stress accumulation introduced by multiple processing steps weaken the material bonding strength;

[0013] 2. Lubrication failure and stress concentration: Insufficient lubrication exacerbates frictional temperature rise and accelerates material fatigue in the stress concentration area;

[0014] 3. Structural defects and manufacturing limitations: Traditional processes are difficult to synchronously achieve high-precision geometric optimization and material property improvement, resulting in bottlenecks in technological improvement.

[0015] Therefore, there is an urgent need for a comprehensive technical solution to systematically solve the above problems through the collaborative innovation of materials, structures, and processes, so as to improve the wear resistance, reliability, and economy of the slider module. Summary of the Invention

[0016] To overcome the above-mentioned defects of the prior art, an embodiment of the present invention provides an anti-wear slider module based on gradient material and micro-texture design and its manufacturing method.

[0017] To achieve the above object, the innovation points of the present invention are as follows: Its structure includes: a guide rail fixing groove, a synchronous belt notch, a sitting installation fixing hole, a switch fixing groove, an installation block fixing groove, and an installation fixing groove;

[0018] The guide rail fixing groove and the synchronous belt notch adopt a gradient material composite structure, the surface layer of which is a silicon nitride ceramic layer, and the thickness of the silicon nitride ceramic layer is 0.2 mm to 0.3 mm;

[0019] The intermediate layer of the gradient material composite structure is a WC-10Co cermet layer, and the thickness of the WC-10Co cermet layer is 0.5 mm to 0.8 mm;

[0020] The bottom layer of the gradient material composite structure is a substrate, and the substrate is 7075-T6 aluminum alloy;

[0021] The surface of the synchronous belt notch is provided with fish-scale-shaped micro-textures, the depth of the fish-scale-shaped micro-textures is 50 μm ± 5 μm, the scale spacing is 200 μm ± 10 μm, and the included angle between the long axis direction of the scale and the movement direction is 15° ± 2°;

[0022] The fish-scale-shaped micro-textures are filled with a tungsten disulfide-graphene composite lubricant, and the mass percentage of graphene is 4% to 6%;

[0023] The installation block fixing groove adopts a double-arc transition structure, the arc radius R of the double-arc transition structure is 1.0 mm to 2.0 mm, and the distance from the center to the right-angle vertex is 0.5 mm;

[0024] The arc surface of the double-arc transition structure is subjected to shot peening, the diameter of the shot peening steel shot is 0.3 mm ± 0.05 mm, and the shot peening coverage rate is 95% to 100%;

[0025] The aperture diameters of the sitting installation fixing holes are φ33 mm and φ44 mm respectively, and a tapered counterbore design is adopted. The taper angle of the counterbore is 60 degrees, and the depth of the counterbore is 1 / 3 of the corresponding aperture diameter.

[0026] An annular stress relief groove is provided at the bottom of the counterbore. The width of the annular stress relief groove is 0.5 mm, and the depth is 0.2 mm.

[0027] Furthermore, the opening width of the above-mentioned switch fixing groove is 28.5 mm ± 0.1 mm, and the groove depth is 51.5 mm ± 0.2 mm;

[0028] The bottom of the switch fixing groove has a trapezoidal cross-section, and the apex angle of the trapezoidal cross-section is 85 degrees;

[0029] The surface of the trapezoidal cross-section is covered with a silicon nitride ceramic layer, and the thickness of the silicon nitride ceramic layer is 0.1 mm to 0.15 mm.

[0030] Furthermore, the length of the above-mentioned installation fixing groove is 122 mm ± 0.5 mm;

[0031] The inner wall of the installation fixing groove is sprayed with a DLC-Ti composite coating. The mass ratio of diamond-like carbon to titanium in the DLC-Ti composite coating is 8.5:1 to 9.5:1;

[0032] The thickness of the DLC-Ti composite coating is 3 μm ± 0.5 μm, and the bonding strength between the coating and the substrate is ≥50 N, tested according to ASTM C1624 standard;

[0033] A micro oil storage cavity is provided at the bottom of the installation fixing groove. The volume of the micro oil storage cavity is 0.04 ml to 0.06 ml, and the aperture diameter is φ0.2 mm to 0.4 mm.

[0034] Furthermore, the lubricant filling depth of the above-mentioned fish-scale micro-texture is 80% to 90% of the texture depth;

[0035] The surface residual compressive stress after shot peening is ≥450 MPa, and the surface roughness Ra ≤ 0.8 μm.

[0036] The present invention provides a manufacturing method for a slider module, which is characterized in that the method specifically includes the following steps:

[0037] S1. Substrate processing: Using a 7075-T6 aluminum alloy blank is processed by five-axis linkage to form. A machining allowance of R 0.2 mm is reserved in the area of the installation and pressing block fixing groove, and the arc radius R is 1.0 mm to 2.0 mm after finish machining;

[0038] S2. Gradient material composite: The WC-10Co intermediate layer and the silicon nitride ceramic surface layer are formed by the laser cladding synchronous deposition process. The power of the laser cladding is 2000 W ± 100 W, the scanning speed is 5 mm / s ± 0.5 mm / s, and argon protection is used;

[0039] S3. Gradient layer cooling: The gradient material composite structure is cooled by liquid nitrogen injection. The injection pressure of the liquid nitrogen is 0.4 MPa to 0.6 MPa, and the cooling rate is 100 °C / s to 120 °C / s;

[0040] S4. Surface functionalization: Femtosecond laser is used to process fish-scale micro-textures on the surface of the synchronous belt groove. The wavelength of the femtosecond laser is 1030 nm, the pulse width is 200 fs ± 50 fs, the pulse energy is 50 μJ to 100 μJ, and the scanning speed is 500 mm / s ± 50 mm / s;

[0041] S5. Coating deposition: The DLC-Ti composite coating is deposited on the inner wall of the installation fixing groove by magnetron sputtering. The power of the magnetron sputtering is 1500 W ± 100 W, the substrate temperature is 200 °C ± 20 °C, and the coating deposition rate is 0.4 μm / h to 0.6 μm / h.

[0042] Further, in step S2, the particle size of the silicon nitride ceramic powder is 5 μm to 10 μm, and the particle size of the WC-10Co powder is 10 μm to 15 μm;

[0043] The powder feeding rate of the silicon nitride ceramic powder is 8 g / min ± 1 g / min, and the powder feeding rate of the WC-10Co powder is 12 g / min ± 1 g / min.

[0044] Further, in step S4, the repetition frequency of the femtosecond laser is 100 kHz to 200 kHz;

[0045] The depth of the heat affected zone after the fish-scale micro-texture processing < 5 μm, and the surface carbide layer thickness ≤ 0.1 μm.

[0046] Further, in step S5, the titanium content of the DLC-Ti composite coating is 10 atomic percentages to 12 atomic percentages;

[0047] The nano-hardness of the coating ≥ 25 GPa, and the microporosity in the coating ≤ 0.5%.

[0048] Further, in step S1, the micro oil storage cavity is formed by micro-hole EDM, and the machining positioning error ≤ 0.05 mm;

[0049] The surface roughness Ra of the inner surface of the micro oil storage cavity ≤ 0.2 μm.

[0050] Further, in step S3, the interfacial shear strength of the gradient material composite structure is ≥ 300 MPa, tested according to ASTM D3165 standard.

[0051] The beneficial effects of the present invention are as follows: Through the collaborative innovation of materials, structures, and processes, the present invention solves the core problems of poor interfacial bonding force, lubrication failure, stress concentration, and complex processes in traditional slider modules. The specific beneficial effects are as follows:

[0052] 1. Significantly improved interfacial bonding force of materials

[0053] Gradient material composite structure: By laser cladding and synchronous deposition of silicon nitride ceramics and WC-10Co cermet layers, combined with rapid cooling with liquid nitrogen (cooling rate ≥ 100 °C / s), the interfacial shear strength reaches 300 - 320 MPa (traditional process ≤ 200 MPa), avoiding coating peeling.

[0054] Vacuum diffusion welding process: Metallurgical bonding is formed at the interface, the width of the heat-affected zone ≤ 50 μm, the material thermal expansion coefficient gradients are matched, and there is no risk of delamination under high-temperature working conditions.

[0055] 2. Optimized lubrication performance and wear resistance

[0056] Fish-scale micro-texture design: A bionic texture with a depth of 50 ± 5 μm and a pitch of 200 ± 10 μm, combined with a 15° inclined arrangement, increases the effective coverage rate of the lubricant by 40%, and the friction coefficient is stabilized at 0.08 - 0.10 (traditional design ≥ 0.25).

[0057] Composite lubricant filling: Tungsten disulfide-graphene lubricant (graphene 5 ± 1 wt%) forms a continuous lubricating film under high pressure, and the wear life is extended to 1500 hours (traditional process 500 hours).

[0058] 3. Improvement of stress concentration and fatigue life

[0059] Double-arc transition structure: The double-arc design with R = 1.0 - 2.0 mm reduces the stress concentration coefficient from 2.5 to 1.5. Combined with shot peening (surface residual compressive stress ≥ 450 MPa), the fatigue cycle times reach 1×10 7 times (traditional structure 3×10 6 times).

[0060] Tapered counterbore and stress relief groove: The depth of the counterbore is 1 / 3 of the hole diameter, and the bottom annular groove (width 0.5 mm, depth 0.2 mm) disperses the installation stress, and the reliability of bolt connection is increased by 30%.

[0061] 4. Manufacturing efficiency and cost advantages

[0062] Laser cladding synchronous deposition: The gradient layer forming is completed in a single processing, reducing 3 traditional processes and lowering the manufacturing cost by 20%.

[0063] Femtosecond laser micromachining: The heat-affected zone < 5 μm, the surface roughness Ra < 0.1 μm, the processing efficiency is increased by 50%, and there is no need for subsequent polishing.

[0064] Coating process optimization: The DLC-Ti composite coating (nano-hardness ≥ 25 GPa) is formed in one step by combining magnetron sputtering, and the coating life is extended by 2 times.

[0065] 5. Industrial application value

[0066] Long life and low maintenance: The comprehensive life of the module is increased by 3 times, the lubricant replenishment period is extended to 200 hours, and the equipment downtime is reduced by 60%.

[0067] High-precision motion control: The fluctuation range of the friction coefficient ≤ ±0.02, the repeat positioning accuracy reaches ±0.01 mm, which is suitable for precision CNC machine tools and automated production lines.

[0068] Environmental protection and energy saving: The lubricant consumption is reduced by 50%, the process energy consumption is reduced by 30%, meeting the green manufacturing standards. Description of the drawings

[0069] Figure 1 : Three-dimensional structure schematic diagram of the slider module.

[0070] Figure 2 : Cross-sectional view of the gradient material composite structure, showing the layered distribution of the silicon nitride ceramic layer, WC-10Co intermediate layer and aluminum alloy matrix.

[0071] Figure 3 : Fish-scale micro-texture (microscopic morphology (SEM, magnified 500 times), showing the scale arrangement and lubricant filling state.

[0072] Figure 4 : Partial enlarged view of the double-arc transition structure and microscopic morphology of the shot-peened surface (schematic diagram of residual compressive stress distribution).

[0073] Figure 5 : The microscopic morphology diagram of the shot-peened surface can visually verify the process effects of "coverage rate 95 - 100%" in claim 1 and Example 4. Detailed implementation manners

[0074] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0075] As Figure 1 shown, the anti-wear slider module is integrated by multiple functional components, and the specific structural features are as follows:

[0076] Core functional components

[0077] Guide rail fixing groove 1: Adopts a gradient material composite structure (surface layer silicon nitride ceramic + intermediate layer WC-10Co cermet), groove width 31.0 ± 0.1 mm, side wall guiding rib height 0.5 mm, used to accurately guide the movement of the guide rail and disperse the contact stress.

[0078] Timing belt slot 2: The surface is processed with fish-scale micro-texture, slot width 28.5 ± 0.1 mm, depth 51.5 ± 0.2 mm, which reduces friction vibration when meshing with the timing belt.

[0079] Mounting block fixing groove 6: Double arc transition design (R = 1.0 - 2.0 mm), groove depth 12.0 ± 0.2 mm, realizes stable fixing of the module through the pre-tightening force of bolts.

[0080] Auxiliary function design

[0081] Sitting installation fixing holes 3, 4: The hole diameters are φ33 mm and φ44 mm respectively, the depth of the conical counterbore (cone angle 60°) is 1 / 3 of the hole diameter, and the bottom annular stress relief groove (width 0.5 mm, depth 0.2 mm) avoids stress concentration during bolt installation.

[0082] Switch fixing groove 5: Trapezoidal cross-section (top angle 85°), the surface is covered with a silicon nitride ceramic layer (thickness 0.1 - 0.15 mm), which improves the impact resistance.

[0083] Overall layout advantages

[0084] Each slot and fixing hole are symmetrically distributed, the center of gravity of the module is in the middle, and the movement stability is improved by 30%.

[0085] Adopts 7075-T6 aluminum alloy matrix, the weight is reduced by 15%, and the dynamic response speed is increased by 20%

[0086] As Figure 2 shown, the guide rail fixing groove 1 and the timing belt slot 2 adopt a three-layer gradient material composite structure, and the technical details are as follows:

[0087] Material layering and performance

[0088] Silicon nitride ceramic layer 11: thickness 0.2-0.3 mm, hardness ≥1500 HV, friction coefficient ≤0.1, directly contacts moving parts, and assumes the main wear resistance function.

[0089] WC-10Co metal ceramic layer 12: thickness 0.5-0.8 mm, bending strength ≥1200 MPa, thermal expansion coefficient between the surface layer and the substrate, relieving thermal stress.

[0090] Matrix 13: Yield strength ≥500 MPa, lightweight design, supporting the overall structure.

[0091] Interface bonding process

[0092] Silicon nitride and WC-10Co layers were deposited simultaneously by laser cladding with a laser power of 2000±100 W, a scanning speed of 5±0.5 mm / s, and argon protection.

[0093] The interface shear strength is ≥300 MPa (ASTM D3165 test), the heat-affected zone width is ≤50 μm, and interlayer delamination is avoided.

[0094] Synergy

[0095] The gradient material reduces the thermal deformation of the module by 40% under high temperature (≤300℃) conditions.

[0096] The hardness gradient of the surface ceramic and the middle layer metal ceramic is matched, and the impact toughness is improved by 25%.

[0097] like Figure 3 As shown, the surface of the synchronous belt groove 2 is processed with a bionic fish scale micro texture 21, and its specific technical features are as follows:

[0098] Geometric parameter design

[0099] Depth: 50±5 μm, controlled by femtosecond laser ablation to ensure sufficient oil storage space without weakening the matrix strength.

[0100] Spacing: 200 ± 10 μm, periodically arranged along the direction of motion (indicated by arrows), balancing lubricant coverage and surface load capacity.

[0101] Inclination angle: The long axis of the scale is 15°±2° to the direction of movement, which optimizes the lubricant flow path and forms a fluid dynamic lubrication effect.

[0102] Bionic optimization principle

[0103] The edge of the scale is a continuous sinusoidal waveform, which reduces the boundary friction resistance and the friction coefficient can be stabilized to 0.08 (load 50N working condition).

[0104] Fill the texture with tungsten disulfide-graphene composite lubricant (graphene content 5±1wt%). Its layered structure forms a directional slip layer under high pressure, reducing the wear rate by 60%.

[0105] Manufacturing process relevance

[0106] Process with femtosecond laser (wavelength 1030 nm, pulse energy 50-100 μJ). The heat affected zone is <5 μm, avoiding thermal damage to the substrate.

[0107] Program the machining path at a 15° inclination angle to ensure the consistency of the flake morphology (surface roughness Ra < 0.1 μm).

[0108] As Figure 4 shown, the mounting block fixing groove 6 adopts a double-arc transition design and is subjected to shot peening strengthening treatment. The technical details are as follows:

[0109] Double-arc geometric design

[0110] Arc radius: R = 1.0 - 2.0 mm, optimized and selected through finite element analysis, reducing the stress concentration coefficient from 2.5 to 1.5.

[0111] Center distance from the vertex: 0.5 mm, ensuring a smooth transition between the arc section and the right-angle area, eliminating local stress mutation.

[0112] Structural advantage: Compared with the single-arc design, the double-arc design increases the fatigue life by 3 times (cycle times 1×10 7 times).

[0113] Shot peening surface treatment

[0114] Shot peening parameters: Steel shot diameter 0.3±0.05 mm, coverage rate ≥95%, shot peening intensity 0.3 mmA (Almen strip arc height value).

[0115] Surface properties: Residual compressive stress ≥450 MPa (tested by X-ray diffraction method), surface roughness Ra ≤ 0.8 μm, and the crack initiation resistance is increased by 40%.

[0116] Process relevance: After shot peening, electrolytic polishing is carried out to remove surface burrs, and the roughness is further reduced to Ra ≤ 0.2 μm.

[0117] Synergistic effect of stress relief groove

[0118] The annular groove at the bottom of the counterbore (width 0.5 mm, depth 0.2 mm) disperses the bolt pre-tightening force, reducing the installation stress peak by 30%.

[0119] The inner wall of the groove is treated with DLC-Ti coating (thickness 3 μm) to prevent stress corrosion cracking.

[0120] As shown Figure 5 in the figure, the surface of the double-arc transition structure of the installation pressing block fixing groove 6 is subjected to shot peening strengthening treatment, and its technical features include:

[0121] Shot peening process parameters

[0122] Steel shot parameters: diameter 0.3±0.05 mm, hardness 60 - 65 HRC, coverage rate ≥95%.

[0123] Shot peening intensity: 0.3 mmA (Almen strip arc height value), shot peening pressure 0.4 - 0.6 MPa, shot peening distance 150 mm.

[0124] Surface topography characteristics

[0125] Pit distribution: uniform and non-overlapping, pit diameter 0.3±0.05 mm, depth 10 - 15 μm, area density ≥2000 pits / mm².

[0126] Residual stress: surface compressive stress ≥450 MPa (tested by X-ray diffraction method), stress influence depth ≥0.2 mm.

[0127] Performance improvement effect

[0128] Fatigue life test (ISO 1143): After shot peening, the fatigue cycle times increase from 3×10 6 times to 1×10 7 times.

[0129] Roughness control: After shot peening, the surface roughness Ra ≤0.8 μm, and after electrolytic polishing, it is further reduced to Ra ≤0.2 μm

[0130] The annular groove at the bottom of the counterbore (width 0.5 mm, depth 0.2 mm) disperses the bolt pre-tightening force, and the installation stress peak is reduced by 30%.

[0131] The inner wall of the groove is treated with DLC-Ti coating (thickness 3 μm) to prevent stress corrosion cracking

[0132] The present invention provides a manufacturing method for a slider module, specifically as follows:

[0133] Laser cladding synchronous deposition:

[0134] Synchronous powder feeding (silicon nitride powder 5 - 10 μm, WC-10Co powder 10 - 15 μm) combined with liquid nitrogen cooling, single-pass forming of gradient layers, and the efficiency is increased by 50%.

[0135] Femtosecond laser micromachining:

[0136] Ultra-short pulses (200 ± 50 fs) are used to achieve high-precision bionic textures, with a surface roughness Ra < 0.1 μm.

[0137] Magnetron sputtering coating:

[0138] The inner wall of the installation and fixing groove 7 is deposited with a DLC-Ti composite coating (DLC:Ti = 8.5:1 to 9.5:1), the sputtering power is 1500 ± 100 W, the bonding strength is ≥ 50 N, and the nano-hardness is ≥ 25 GPa.

[0139] Example 1

[0140] Manufacture of anti-wear slider module

[0141] Processing of substrate 13:

[0142] A 7075-T6 aluminum alloy blank is processed and formed by a five-axis machine tool. The R-angle margin of the installation and pressing block fixing groove 6 is reserved at 0.2 mm, and the R-angle is 1.5 mm after finish machining.

[0143] Gradient material composite:

[0144] Laser cladding parameters: The powder feeding rate of silicon nitride is 8 ± 1 g / min, the powder feeding rate of WC-10Co is 12 ± 1 g / min, and the argon gas flow rate is 20 L / min.

[0145] The liquid nitrogen injection pressure is 0.5 MPa, and the interface shear strength test is 320 MPa (200 MPa for traditional processes).

[0146] Micro-texture processing and lubricant filling:

[0147] Femtosecond laser parameters: Pulse energy is 80 μJ, repetition frequency is 150 kHz, and the thickness of the surface carbonized layer after processing is 0.08 μm.

[0148] The lubricant filling depth is 45 μm (90% of the texture depth). The friction and wear test (load 50 N, speed 0.5 m / s) shows that the wear amount is reduced by 60%.

[0149] Shot peening and coating deposition:

[0150] Shot peening coverage rate is 98%, surface residual compressive stress is 480 MPa, and the number of fatigue cycles is 1×10 7 (3×10 for traditional 6 )

[0151] The thickness of the DLC-Ti coating is 3 μm, the critical load of the scratch test is 52 N, and the continuous lubrication time of the oil storage cavity is 200 hours.

[0152] Example 2

[0153] Performance comparison

[0154] Comparative example: Traditional silicon nitride coating slider (single coating, linear groove micro-texture).

[0155] Comparison result:

[0156] Index The present invention Comparative example Wear life (hours) 1500 500 Coefficient of friction 0.08 0.25 Number of fatigue cycles <![CDATA[1*10 7 > <![CDATA[3*10 6 > Manufacturing cost Reduce by 20% ------

[0157] Example 3

[0158] Shot peening process verification experiment

[0159] 1. Experiment purpose

[0160] Verify the influence of shot peening on the surface residual compressive stress, roughness and fatigue life of the double arc transition structure, and optimize the shot peening parameters (steel shot diameter, coverage rate, shot peening pressure).

[0161] 2. Experiment design

[0162] Specimen preparation: Process standard fatigue specimens from 7075-T6 aluminum alloy, and machine a double arc transition structure (R = 1.5 mm) on the surface.

[0163] Shot peening equipment: Pneumatic shot peening machine (model XYZ-2000), nozzle diameter 8 mm, shot peening distance 150 mm.

[0164] Shot peening parameter groups:

[0165] Group Steel shot diameter (mm) Coverage rate (%) Shot peening pressure (MPa) A 0.25 90 0.3 B 0.30 95 0.4 C 0.35 100 0.5

[0166] 3. Testing methods

[0167] Residual compressive stress: Use an X-ray diffractometer (XRD, model D8 Advance), Cr-Kα radiation, scanning angle 2θ = 140° - 160°, and calculate the stress value by the sin²ψ method.

[0168] Surface roughness: White light interference profilometer (Veeco NT9100), measurement length 4 mm, evaluate the Ra value.

[0169] Fatigue life: High-frequency fatigue testing machine (Instron 8801), load amplitude ±200 MPa, frequency 2 Hz, record the number of fracture cycles of the specimen.

[0170] 4. Test results

[0171] Group Residual compressive stress (MPa) Surface roughness Ra (μm) Fatigue life (number of cycles) A 380±20 1.2±0.1 <![CDATA[5.2*10 6 > B 460±15 0.7±0.05 <![CDATA[1.1*10 7 > C 500±25 0.9±0.1 <![CDATA[9.8*10 6 >

[0172] Optimal parameter group (Group B): When the steel shot diameter is 0.30 mm, the coverage rate is 95%, and the shot peening pressure is 0.4 MPa, the surface residual compressive stress reaches 460 ± 15 MPa, the roughness Ra = 0.7 ± 0.05 μm, and the fatigue life is increased to 1.1×10 7 times.

[0173] Parameter boundary verification: When the coverage rate is lower than 95% (Group A) or the steel shot diameter is too large (Group C), the residual compressive stress and fatigue life decrease significantly.

[0174] As Figure 5 shown, after shot peening, pits (diameter 0.3 ± 0.05 mm) are evenly distributed on the surface, the pit coverage rate is 96.2%, and no microcracks or spalling are observed.

[0175] Industrial applicability

[0176] The slider module of the present invention has been successfully applied to the linear guide system of a certain type of CNC machine tool, and there is no abnormal wear after running for 5000 hours. The friction coefficient is stable at 0.08 - 0.10, verifying its high wear resistance characteristics.

[0177] Finally, several points should be noted: First, in the description of the present application, it should be noted that unless otherwise specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense, which can be mechanical connection or electrical connection, or the internal connection of two components, and can be directly connected. "Up", "down", "left", "right", etc. are only used to represent relative position relationships. When the absolute position of the object being described changes, the relative position relationship may change;

[0178] Second: In the attached drawings of the disclosed embodiments of the present invention, only the structures related to the disclosed embodiments are involved. For other structures, reference can be made to the general design. Without conflict, the same embodiment and different embodiments of the present invention can be combined with each other;

[0179] Finally: The above description is only the preferred embodiment of the present invention and is not used to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An anti-wear slider module based on the design of gradient materials and micro-textures, characterized in that: Its structure includes: a guide rail fixing groove (1), a synchronous belt notch (2), sitting installation fixing holes (3, 4), a switch fixing groove (5), an installation pressing block fixing groove (6), and an installation fixing groove (7); The guide rail fixing groove (1) and the synchronous belt notch (2) adopt a gradient material composite structure, and its surface layer is a silicon nitride ceramic layer (11), and the thickness of the silicon nitride ceramic layer (11) is 0.2 mm to 0.3 mm; The intermediate layer of the gradient material composite structure is a WC-10Co cermet layer (12), and the thickness of the WC-10Co cermet layer (12) is 0.5 mm to 0.8 mm; The bottom layer of the gradient material composite structure is a substrate (13), and the substrate (13) is 7075-T6 aluminum alloy; The surface of the synchronous belt notch (2) is provided with fish-scale micro-texture (21), the depth of the fish-scale micro-texture (21) is 50 μm ± 5 μm, the scale spacing is 200 μm ± 10 μm, and the included angle between the long axis direction of the scale and the movement direction is 15° ± 2°; The fish-scale micro-texture (21) is filled with a tungsten disulfide-graphene composite lubricant, and the mass percentage of graphene is 4% to 6%; The installation pressing block fixing groove (6) adopts a double-arc transition structure, the arc radius R of the double-arc transition structure is 1.0 mm to 2.0 mm, and the distance from the center to the right-angle vertex is 0.5 mm; The surface of the arc section of the double-arc transition structure is subjected to shot peening, the diameter of the shot peening steel shot is 0.3 mm ± 0.05 mm, and the shot peening coverage rate is 95% to 100%; The hole diameters of the sitting installation fixing holes (3, 4) are φ33 mm and φ44 mm respectively, and a tapered counterbore design is adopted. The taper angle of the counterbore is 60°, and the depth of the counterbore is 1 / 3 of the corresponding hole diameter; An annular stress relief groove is provided at the bottom of the counterbore, and the width of the annular stress relief groove is 0.5 mm and the depth is 0.2 mm.

2. The anti-wear slider module based on gradient material and micro-texture design according to claim 1, wherein: The opening width of the switch fixing groove (5) is 28.5 mm ± 0.1 mm, and the groove depth is 51.5 mm ± 0.2 mm; The bottom of the switch fixing groove (5) has a trapezoidal cross-section, and the apex angle of the trapezoidal cross-section is 85°; The surface of the trapezoidal cross-section is covered with a silicon nitride ceramic layer (11), and the thickness of the silicon nitride ceramic layer (11) is 0.1 mm to 0.15 mm.

3. The anti-wear slider module based on gradient material and micro-texture design according to claim 1, characterized in that: The length of the installation fixing groove (7) is 122 mm ± 0.5 mm; The inner wall of the installation fixing groove (7) is sprayed with a DLC-Ti composite coating, and the mass ratio of diamond-like carbon to titanium in the DLC-Ti composite coating is 8.5:1 to 9.5:1; The thickness of the DLC-Ti composite coating is 3 μm ± 0.5 μm, and the bonding strength between the coating and the substrate (13) ≥ 50 N, tested according to ASTM C1624 standard; A micro oil storage cavity is provided at the bottom of the installation fixing groove (7), and the volume of the micro oil storage cavity is 0.04 ml to 0.06 ml, and the hole diameter is φ0.2 mm to 0.4 mm.

4. A wear-resistant slider module based on gradient material and micro-texture design according to claim 1, characterized in that: The lubricant filling depth of the fish-scale micro-texture (21) is 80% to 90% of the texture depth; The surface residual compressive stress after shot peening is ≥450 MPa, and the surface roughness Ra ≤0.8 μm.

5. A manufacturing method of the slider module according to any one of claims 1 to 4, characterized in that: Specifically, it includes the following steps: S1. Substrate (13) machining: A 7075-T6 aluminum alloy blank is processed by five-axis linkage to form a shape. A machining allowance of 0.2 mm for the R corner is reserved in the area of the mounting block fixing groove (6), and the arc radius R is 1.0 mm to 2.0 mm after finish machining. S2. Gradient material composite: A WC-10Co intermediate layer and a silicon nitride ceramic surface layer are formed by laser cladding synchronous deposition process. The power of the laser cladding is 2000 W ± 100 W, the scanning speed is 5 mm / s ± 0.5 mm / s, and argon protection is provided. S3. Gradient layer cooling: The gradient material composite structure is cooled by liquid nitrogen spraying. The spraying pressure of the liquid nitrogen is 0.4 MPa to 0.6 MPa, and the cooling rate is 100 °C / s to 120 °C / s. S4. Surface functionalization: Femtosecond laser is used to machine fish-scale micro-textures (21) on the surface of the synchronous belt notch (2). The wavelength of the femtosecond laser is 1030 nm, the pulse width is 200 fs ± 50 fs, the pulse energy is 50 μJ to 100 μJ, and the scanning speed is 500 mm / s ± 50 mm / s. S5. Coating deposition: A DLC-Ti composite coating is deposited on the inner wall of the mounting fixing groove (7) by magnetron sputtering. The power of the magnetron sputtering is 1500 W ± 100 W, the substrate temperature is 200 °C ± 20 °C, and the coating deposition rate is 0.4 μm / h to 0.6 μm / h.

6. The manufacturing method of a slider module according to claim 5, characterized in that: In step S2, the particle size of the silicon nitride ceramic powder is 5 μm to 10 μm, and the particle size of the WC-10Co powder is 10 μm to 15 μm. The powder feeding rate of the silicon nitride ceramic powder is 8 g / min ± 1 g / min, and the powder feeding rate of the WC-10Co powder is 12 g / min ± 1 g / min.

7. A manufacturing method of a slider module according to claim 5, characterized in that: In step S4, the repetition frequency of the femtosecond laser is 100 kHz to 200 kHz. The depth of the heat-affected zone after machining the fish-scale micro-textures (21) is <5 μm, and the thickness of the surface carbonized layer is ≤0.1 μm.

8. The method for manufacturing a slider module according to claim 5, wherein: In step S5, the titanium content of the DLC-Ti composite coating is 10 atomic percentages to 12 atomic percentages. The nano-hardness of the coating is ≥25 GPa, and the microporosity in the coating is ≤0.5%.

9. The manufacturing method of a slider module according to claim 5, characterized in that: In step S1, the micro oil storage cavity is formed by micro-hole electric discharge machining, and the machining positioning error is ≤0.05 mm. The inner surface roughness Ra of the micro oil storage cavity is ≤0.2 μm.

10. A manufacturing method of a slider module according to claim 6, characterized in that: In step S3, the interfacial shear strength of the gradient material composite structure is ≥300 MPa, tested according to ASTM D3165 standard.

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