碳化硅盲槽微细铣削对比实验研究

Comparative experimental study on micromilling of SiC blind slots

  • 摘要: 碳化硅(silicon carbide, SiC)材料微小型几何结构的高质量切削加工难度极大,目前相关研究较少。文章针对碳化硅材料盲槽几何结构,分别利用自研聚晶金刚石(polycrystalline diamond, PCD)微细铣刀、外购PCD微细铣刀和外购PCD涂层微细铣刀,进行对比实验,为后续深入研究SiC微细铣削工艺提供参考。实验结果显示,外购PCD涂层微细铣刀因涂层脱落、崩刃引发断刀,故未再分析。自研PCD微细铣刀切削力更稳定且小于外购刀;其底刃磨损量亦小于外购刀。表面形貌表明,自研刀实现完全塑性切削,外购刀为脆性-塑性混合去除。自研刀加工槽底表面粗糙度Sa为4.931 μm,约为外购刀的一半。对比证实,自研PCD微细铣刀在SiC盲槽微细铣削中,其耐用性、加工稳定性及表面质量优势明显,为进一步深入研究微细铣削碳化硅提供了较好的刀具解决方案。

     

    Abstract: With the increasingly widespread high-end applications of silicon carbide (SiC) materials, high-quality machining of micro-scale geometric structures is urgently needed. However, limited research has been conducted on this topic so far. In this study, comparative micromilling experiments are performed on blind slot geometries in SiC materials using three types of tools: a self-developed polycrystalline diamond (PCD) micromilling cutter, a commercially available PCD micromilling cutter, and a commercially available PCD-coated micromilling cutter, with the aim of providing a reference for further research on SiC micromilling processes. Experimental results reveal that the commercial PCD-coated micromilling cutters suffered failure due to coating delamination and edge chipping, which precluded further analysis. It is demonstrated that the self-developed PCD micromilling cutters exhibited more stable cutting forces with lower values than commercial PCD micromilling cutters, as well as less bottom edge wear. Surface morphology analysis indicates that fully ductile-mode cutting was achieved by the self-developed tools, whereas mixed brittle-ductile material removal occurred in the case of commercial PCD micromilling cutters. The surface roughness (Sa) of slots machined by self-developed tools was measured as 4.931 μm, approximately half that of those machined by commercial PCD micromilling cutters. Through comparative analysis, it is confirmed that the self-developed PCD micromilling cutters demonstrate significant advantages in durability, machining stability, and surface quality for micromilling SiC blind slots, thus providing an effective tooling solution for advancing SiC micro-machining research.

     

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