3 Challenges faced by domestic high-speed cutting tool materials
Domestic high-speed cutting tool materials have a large gap with foreign countries. At present, the tools used in imported and domestically produced high-speed machine tools mainly rely on imports, so domestic high-speed cutting tool materials face severe challenges.
At present, the most commonly used general-purpose tools in China are mainly high-speed steel (W18Cr4V), which are mostly produced by smaller manufacturers. High-performance high-speed steel such as aluminum high-speed steel and cobalt high-speed steel are of poor quality and are rarely used. Powder metallurgy high speed steel tools are still under study, and the cutting speed is generally 25 to 40 m/min. Cars, milling, boring and end mills are commonly used for hard alloys, but most of the welding knives are mainly ordinary hard alloys (TG, YT). Although the indexable insert has WC plus TaC, NbC or Hf-Nb, and ultra-fine cemented carbide products, the application is still not common, and the cutting speed is 100-200 m/min. Hard alloys such as deep hole drills and thread cutters have also been available in recent years, but their applications are less and the processing efficiency is generally low.
The most advantageous of domestic high-speed cutting tools is ceramic knives, and the level of research and development is comparable to that of the international. At present, there are more than 30 varieties of ceramic tools, including more than 20 alumina bases and nearly 10 silicon nitride bases. The production capacity of ceramic tools with and without holes is also very large.
We have closely combined cutting science and tool material science for decades. After in-depth research, we have established a new research system for ceramic tools based on cutting reliability, fusion of ceramic tool cutting theory and tool material research and development. Now we can optimize the design and obtain the ceramic cutting tool material with excellent performance, and we are making a breakthrough in the international frontier position of the combination of computer-aided design and hot-pressing process simulation of ceramic tool materials. The traditional research and development model accelerates the research and development of ceramic tools. Based on this theory, we have successfully developed 6 varieties of 12 grades of Al2O3 based ceramic tool materials, which have been put on the market, including aluminum-titanium (LT), whisker (JX), boron-titanium (LP), special powder and Rare earth LD series, gradient function (FG) and ceramic-hard alloy composite sheet (FH) series. The mechanical properties and wear and break resistance of the FG and FH series are significantly improved, extending tool life. JX-2, LP-2, gradient function FG, ceramic-hard alloy composite sheet (FH) and LD-1 with special powder in the six varieties are synergistically toughened to fill the domestic gap. No reports have been reported abroad. The mechanical properties and cutting performance of domestic ceramic tool products are comparable to those of foreign countries, and some are better. Domestic ceramic tools can turn or mill steel, alloy steel, cast iron and alloy cast iron at high speeds of 300-1000m/min. Among these Al2O3-based varieties, SG-4, FG-2 and FH-2 are currently domestic. The ideal tool material for high-speed machining of hardened steel (55-65HRC). The silicon nitride-based ceramic insert developed in China has excellent performance and has superior advantages in processing cast iron. Sialon ceramic tools are also available. The main difference in the existence of ceramic tools is that the precision and appearance quality of high-precision ceramic blades are still not good, and some varieties are not yet available. The promotion and application are far less common in developed countries.
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