Ceramic Ball Surface Roughness Control for Uniform Sintering
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Solution Overview
Problem
Ceramic ball materials exhibit microstructural unevenness due to uneven formation during powder press forming, leading to defects in the polishing process.
Innovation Solution
A ceramic ball material with a specific ratio of arithmetic average roughness (Rab/Rap) between 0.70 and 1.03 is used, which suppresses microstructural unevenness during sintering, thereby reducing defects in the polishing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If powder press forming is used to form green compact, then the ceramic ball material can be manufactured, but microstructural unevenness occurs due to uneven formation
Solution Approach 1:
The invention applies preliminary action by forming a spherical portion and a band-shaped portion with different arithmetic average roughness values (Rab/Rap between 0.70-1.03) before sintering. This preliminary differentiation of surface roughness in the green compact state prevents microstructural unevenness during sintering, as the band-shaped portion with higher roughness sinteres at a different rate than the spherical portion, achieving uniform microstructure in the final sintered product.
2Productivity
If sintering is performed on green compact with spherical portion and band-shaped portion, then ceramic ball material is obtained, but microstructural unevenness and defects remain
Solution Approach 1:
The invention applies parameter changes by precisely controlling the ratio of arithmetic average roughness (Rab/Rap) between the band-shaped portion and spherical portion within 0.70-1.03. This parameter optimization ensures that during sintering, the different portions contract uniformly, preventing microstructural unevenness and defects while maintaining high production efficiency.
3Shape
If polishing is performed on ceramic ball material with microstructural unevenness, then spherical shape is achieved, but processing yield decreases due to defects
Solution Approach 1:
The invention applies preliminary anti-action by creating controlled surface roughness differences (Rab/Rap = 0.70-1.03) in the green compact before sintering, which counteracts the tendency toward microstructural unevenness during sintering. This preliminary preventive measure eliminates the root cause of polishing defects, thereby improving processing yield while maintaining spherical shape.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The ceramic ball material achieves a high processing yield in polishing by minimizing microstructural unevenness and defects, resulting in a more efficient and effective polishing process.
Implementation Method 1
a method of sintering a green compact is employed
Data Source
AI summary
A ceramic ball material according to an embodiment includes a spherical portion; and a band-shaped portion formed over a circumference of a surface of the spherical portion. In the ceramic ball material, the ceramic ball material has a ratio Rab/Rap of 0.70 or more and 1.03 or less, where Rab denotes an arithmetic average roughness on an outer peripheral surface of the band-shaped portion; and Rap denotes an arithmetic average roughness on an outer peripheral surface of the spherical portion.