Sintered Body Thermal Conductivity for Nickel Alloy Cutting
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Solution Overview
Problem
Sintered bodies used for cutting nickel-based heat-resistant alloys face challenges with low fracture resistance while maintaining high wear resistance, leading to tool failure during high-precision cutting applications like aircraft and automobile engine components.
Innovation Solution
A sintered body comprising cubic boron nitride grains, a binder, and additional hard phase grains such as silicon nitride or SiAlON, with a thermal conductivity range of 15-40 W·m^-1·K^-1, is developed to enhance both wear and fracture resistance for cutting tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sintered body containing cubic boron nitride is used for cutting nickel-based heat-resistant alloys, then wear resistance is improved, but fracture resistance deteriorates
Solution Approach 1:
The sintered body uses a composite structure containing cubic boron nitride grains (providing wear resistance), silicon nitride or SiAlON grains (providing fracture resistance), and a binder phase. This composite material approach allows simultaneous achievement of high wear resistance and high fracture resistance by combining materials with complementary properties.
Solution Approach 2:
The invention creates local quality differentiation within the sintered body by distributing different hard phase grains (cubic boron nitride, silicon nitride, SiAlON) throughout the binder matrix. Each grain type contributes its specific properties locally, with cubic boron nitride providing wear resistance at contact points and silicon nitride/SiAlON providing fracture resistance in stress-bearing regions.
2Duration of action of moving object
If the sintered body contains high content of cubic boron nitride for high wear resistance, then cutting edge durability is improved, but tool fracture becomes more likely
Solution Approach 1:
The sintered body employs a composite material system where cubic boron nitride grains (60-93 vol%) provide cutting edge durability through high wear resistance, while silicon nitride or SiAlON grains (7-40 vol%) provide fracture resistance. The binder phase binds these hard grains together, creating a balanced composite that achieves both extended cutting edge life and reduced tool fracture risk.
Data Source
AI summary
A sintered body includes cubic boron nitride grains as hard phase grains, and has a thermal conductivity of not less than 15 W·m-1·K-1 and not more than 40 W·m-1·K-1, for cutting a nickel-based heat-resistant alloy formed of crystal grains having a fine grain size represented by a grain size number of more than 5 defined by ASTM standard E112-13, A cutting tool includes this sintered body. Accordingly, the sintered body having both high wear resistance and high fracture resistance, as well as the cutting tool including the sintered body are provided.