2.5D SiCf/SiC陶瓷基复合材料双面磨削表面质量均匀性研究

Study on surface quality uniformity of 2.5D SiCf/SiC ceramic matrix composites in double-sided grinding

  • 摘要: 2.5D SiCf/SiC陶瓷基复合材料具有硬度高、脆性大和非均质等特性,属于典型的难加工材料。为揭示双面磨削工艺对2.5D SiCf/SiC陶瓷基复合材料表面质量的影响机制,实现表面质量的精准调控,通过系列磨削实验,定量分析砂纸目数对材料去除率(material removal rate, MRR)、表面粗糙度(Sa)、损伤均匀性及上、下表面加工质量一致性的影响规律。结果表明,砂纸目数从360目提升至3 000目,材料去除率显著下降,且当目数达到3 000目时,磨粒作用以修整为主,材料已无明显宏观去除;更大目数砂纸加工后材料去除率未出现明显变化,表明3 000目砂纸去除能力已趋饱和。厚度及表面粗糙度表征结果也证明3 000目砂纸对表面质量的调控作用趋于饱和。在表面损伤演化方面,360目砂纸磨削表面存在大量纤维破碎剥落与基体脆性断裂痕迹;1 200目砂纸磨削基体脆性去除特征显著减少,纤维断裂形态更趋规整;3 000目与4 000目砂纸进一步抑制损伤,表面以“塑性去除/轻微脆性剥离”为主,但二者损伤抑制效果无明显差异。研究可为2.5D SiCf/SiC陶瓷基复合材料高效双面磨削及其工艺优化提供参考。

     

    Abstract: 2.5D SiCf/SiC ceramic matrix composites exhibit characteristics such as high hardness, high brittleness, and heterogeneity, making them typical difficult-to-machine materials. To reveal the influence mechanism of planetary double-sided grinding process on the surface quality of 2.5D SiCf/SiC ceramic matrix composites and achieve precise control of surface quality, a series of grinding experiments were conducted to quantitatively analyze the influence of sandpaper grit size on material removal rate (MRR), surface roughness (Sa), damage uniformity, and upper-lower surface consistency. The results showed that as the sandpaper grit size increases from 360 to 3 000, the material removal rate decreases significantly; when the grit size reaches 3 000, the abrasive action is mainly focused on dressing, and there is no obvious macroscopic material removal. The material removal rate does not change significantly after processing with sandpaper of higher grit sizes, indicating that the removal capacity of 3 000-grit sandpaper has tended to saturation. The characterization results of thickness and surface roughness also confirm that the regulatory effect of 3 000-grit sandpaper on surface quality tends to saturation. In terms of surface damage evolution: the surface ground by 360-grit sandpaper shows a large number of traces of fiber breakage and spalling as well as matrix brittle fracture. The characteristics of matrix brittle removal in the surface ground by 1 200-grit sandpaper are significantly reduced, and the fiber fracture morphology becomes more regular. 3 000-grit and 4 000-grit sandpapers further inhibit damage, and the surface is dominated by "plastic flow/mild brittle spalling", but there is no significant difference in the damage inhibition effect between the two. This study can provide a reference for efficient double-sided grinding and process optimization of 2.5D SiCf/SiC ceramic matrix composites.

     

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