Abstract
Zirconia ceramics are widely used in many fields because of their excellent physical and mechanical properties. However, there are some challenges to machine zirconia ceramics with high processing efficiency. In order to optimize parameters for milling zirconia ceramics by polycrystalline diamond tool, finite element method was used to simulate machining process based on Johnson-Cook constitutive model. The effects of spindle speed, feed rate, radial and axial cutting depth on cutting force, tool flank wear and material removal rate were investigated. The results of the simulation experiment were analyzed and optimized by the response surface method. The optimal parameter combination was obtained when the spindle speed, feed rate, radial and axial cutting depth were 8000 r/min, 90.65 mm/min, 0.10 mm and 1.37 mm, respectively. Under these conditions, the cutting force was 234.81 N, the tool flank wear was 33.40 μm when the milling length was 60 mm and the material removal rate was 44.65 mm3/min.
Highlights
Zirconia ceramics are characterized by high toughness, high bending strength, high wear resistance, excellent heat insulation, well corrosion resistance and biocompatibility [1,2,3], which have been expansively used in many areas such as aerospace, precision machinery and biomedicine [4,5,6,7,8]
Polycrystalline diamond (PCD) tool has the advantages of high hardness, good thermal conductivity, low friction coefficient and low thermal expansion coefficient, which is an ideal tool for milling zirconia ceramics [11,12]
A lot of research about surface quality, tool wear and material removal rate has been done when zirconia ceramics are machined by PCD tool [13,14,15]
Summary
Zirconia ceramics are characterized by high toughness, high bending strength, high wear resistance, excellent heat insulation, well corrosion resistance and biocompatibility [1,2,3], which have been expansively used in many areas such as aerospace, precision machinery and biomedicine [4,5,6,7,8]. A lot of research about surface quality, tool wear and material removal rate has been done when zirconia ceramics are machined by PCD tool [13,14,15]. Eleonora et al [16] investigated the effects of cutting parameters on surface quality and tool wear cutting parameters on high speed hard cutting with PCD tool. Deng et al [22] simulated the process of diamond fly-cutting zirconia ceramics, and studied the influence of tool geometric parameters and cutting parameters on stress distribution, brittle-plastic transition depth, cutting force and chip morphology. The response surface method was used to analyze the effect of cutting parameters on cutting force, tool flank wear and material removal rate. The optimized parameter combination was obtained for the cutting force, tool flank wear, and material removal.
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