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Chemical unloading and chemical addition.----S.S. lobe pump
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Preparation of starch glue and feeding and conveying of starch.----S.S. lobe pump
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How to choose the correct choice of ceramic tool materials
**Abstract**
New tool materials with great potential are becoming increasingly important in modern manufacturing. As science and technology advance, new difficult-to-machine materials are being widely used across various industries. Traditional carbide tools are no longer sufficient to meet the demands of high-performance machining, while ceramic tools have emerged as a superior alternative. These tools exhibit excellent heat resistance, wear resistance, and chemical stability, making them highly efficient for high-speed cutting and processing of challenging materials.
Ceramic tools offer significant advantages over conventional carbide tools. For instance, when machining materials such as hardened steel, cast iron, or nickel-based superalloys, ceramic tools can last several times longer than their carbide counterparts. They are not only suitable for general turning, boring, and milling but also for more specialized applications like hole machining. Their use in CNC machines and machining centers is well recognized, and they are considered one of the most promising tools for enhancing productivity in modern manufacturing.
Compared to superhard materials like diamond or cubic boron nitride, ceramic tools are more cost-effective. The raw materials used in ceramics, such as alumina and silica, are abundant and easily accessible. This makes ceramic tools an attractive option for many industrial applications. Some experts predict that, as ceramic tool performance continues to improve, they will become one of the three main tools for high-speed cutting, dry cutting, and hard machining—alongside coated carbide tools, diamond, and cubic boron nitride.
Figure 1 illustrates an example of a carburized hardened transmission gear (57–59 HRC) that was hard-turned using a ceramic cutter instead of being ground. This demonstrates the effectiveness of ceramic tools in precision machining. Another image (Figure 2) highlights the properties and classifications of ceramic tool materials.
**Performance of Ceramic Tool Materials**
Ceramic tools are known for their exceptional hardness, reaching up to 92–95 HRA, and their outstanding wear resistance. When machining steel under similar conditions, ceramic tools show significantly less wear compared to P10 (YT15) carbide tools, resulting in a much longer service life. Additionally, ceramic tools have low affinity with metals like steel, which reduces adhesion and built-up edge formation during cutting. This leads to better surface finish and improved machining efficiency.
These tools also possess remarkable heat resistance, maintaining a hardness of around 80 HRA at temperatures up to 1,200°C. This makes them ideal for high-speed and dry cutting operations. Compared to diamond or cubic boron nitride tools, ceramic tools are more affordable and offer comparable performance, making them a practical choice for many applications.
Despite their advantages, ceramic tools do have some limitations. They are generally more brittle than other materials, with lower flexural strength and fracture toughness. However, recent advances in material science and manufacturing techniques have helped overcome these challenges. By controlling grain size, using advanced sintering methods, and incorporating reinforcing elements like carbides and oxides, ceramic tools have seen significant improvements in toughness and durability.
**Classification of Ceramic Tool Materials**
Modern ceramic tools are typically composite materials, designed with different microstructures and toughening mechanisms. The most commonly used types include Al₂O₃-based and Si₃N₄-based ceramics, each with unique properties and applications.
Al₂O₃-based ceramics are widely used due to their high hardness and wear resistance. Variants such as Al₂O₃/TiC composites, nano-cermets, and Al₂O₃/SiC whisker-toughened ceramics are suitable for a wide range of materials, including steels, cast irons, and high-temperature alloys. On the other hand, Si₃N₄-based ceramics excel in applications involving interrupted cutting and high-temperature environments, especially for cast iron and nickel-based superalloys.
Sialon ceramics, a type of Si₃N₄-based material, offer excellent thermal shock resistance and oxidation stability, making them ideal for roughing and finishing operations on difficult-to-machine materials.
**How to Choose Ceramic Tool Materials**
Selecting the right ceramic tool depends on the material being machined, the cutting conditions, and the desired outcome. Al₂O₃-based ceramics are best suited for high-speed machining of steels and cast irons, while Si₃N₄-based ceramics are preferred for cast iron and high-temperature alloys. Sialon ceramics are particularly effective for machining various types of cast iron and heat-resistant alloys.
It’s also important to consider the specific requirements of the machining process, such as cutting speed, feed rate, and tool life. Testing and adjusting the blade grade on the machine before full-scale application is recommended to ensure optimal performance.
**Application Recommendations**
Ceramic tools have revolutionized traditional machining processes and are now widely used across multiple industries, including aerospace, automotive, energy, and precision engineering. Their ability to handle difficult materials and achieve high productivity has made them indispensable in modern manufacturing.
China has been at the forefront of ceramic tool development since the 1950s. Composite blades made from ceramic and cemented carbide combine the benefits of both materials, offering higher strength and better impact resistance. New developments such as ZrOâ‚‚-based and TiBâ‚‚-based ceramics are showing promise for machining aluminum alloys and other challenging materials.
To fully utilize the benefits of ceramic tools, machine tools must be equipped with high stiffness, power, and precision. Proper clamping and vibration control are also essential to prevent tool damage and ensure consistent results.
In summary, ceramic tools represent a significant advancement in machining technology. With ongoing improvements in material properties and manufacturing techniques, they are expected to play an even greater role in the future of industrial production.