氧化铝陶瓷加工边缘破碎机理与抑制方法研究

  氧化铝陶瓷因其高硬度、强度、耐磨性以及耐高温性等优良材料性能被广泛应用，但高硬脆性也带来了一系列加工挑战，特别是在加工表面的边缘处，会出现严重的破碎现象，这是加工中的应力状态与裂纹扩展导致的，这种现象极大地降低了氧化铝陶瓷制品的寿命与可靠性。本研究从加工过程中动态应变率的角度出发，探究了边缘破碎机理，分析得出高应变率能改善应力分布与降低裂纹深度，并据此通过超高速加工技术来实现边缘破碎的抑制。本研究的主要内容如下：

  开展了磨削速度5 m/s~30 m/s下的氧化铝陶瓷平面磨削实验，结果显示，随着磨削速度提高，边缘破碎尺度、磨削力、表面粗糙度和亚表面损伤深度均呈现下降趋势，表明提高磨削速度能减小边缘破碎程度。

  建立了基于Johnson-Holmquist-Ⅱ本构的氧化铝陶瓷超高速单点划擦仿真模型，根据仿真结果，边缘破碎机理可以解释为：亚表面裂纹向自由表面扩展引起的边缘材料脱落。同时随着划擦速度的提高，边缘破碎程度减轻，应力分布得到改善，亚表面裂纹深度减小，动态屈服强度上升。

  进行了20 m/s~220 m/s下的氧化铝陶瓷超高速单点划擦实验，随着划擦速度从20 m/s提高到220 m/s，相同划擦深度下，边缘破碎尺度从58.7 μm下降到16.8 μm，表明超高速加工能有效减小边缘破碎尺度。对堆积比与亚表面裂纹进行了表征，随着划擦速度提高，堆积比从0.78下降到0.45，亚表面侧向裂纹深度从7.3 μm下降到4.9 μm。

  讨论了氧化铝陶瓷加工边缘破碎机理与抑制方法：高应变率下的材料脆化导致了非弹性变形区半径减小，材料侧流现象减弱，降低了侧向裂纹影响范围，进而抑制了边缘破碎。同时，在实际加工中，通过超高速加工带来的高应变率可以有效降低加工损伤层深度，实现边缘破碎的抑制。

  通过综合考虑材料动态性能、亚表面应力状态以及裂纹扩展，建立了基于应变率效应的硬脆材料加工边缘破碎预测模型。得到了亚表面弹性应力场、非弹性变形区半径，确定了侧向裂纹在非弹性变形区边界处，以与表面呈33.5°夹角的方式产生。对比了边缘破碎尺度模型预测值与实验实测值，结果显示模型误差在8 %以内，能够为加工过程的优化提供指导。

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