Shahzamanian M M, Akhtar S S, Arif A F M, Basirun W J, Al-Athel K S, Schneider M, Shakelly N, Hakeem Abbas Saeed, Abubakar Abba A, Wu P D
Department of Mechanical Engineering, McMaster University, Hamilton, ON, Canada.
Department of Mechanical Engineering, King Fahd University of Petroleum & Minerals (KFUPM), Dhahran, Saudi Arabia.
Sci Rep. 2022 Jun 30;12(1):11076. doi: 10.1038/s41598-022-14685-x.
For effective cutting tool inserts that absorb thermal shock at varying temperature gradients, improved thermal conductivity and toughness are required. In addition, parameters such as the coefficient of thermal expansion must be kept within a reasonable range. This work presents a novel material design framework based on a multi-scale modeling approach that proposes nickel (Ni)-reinforced alumina (AlO) composites to tailor the mechanical and thermal properties required for ceramic cutting tools by considering numerous composite parameters. The representative volume elements (RVEs) are generated using the DREAM.3D software program and the output is imported into a commercial finite element software ABAQUS. The RVEs which contain multiple Ni particles with varying porosity and volume fractions are used to predict the effective thermal and mechanical properties using the computational homogenization methods under appropriate boundary conditions (BCs). The RVE framework is validated by the sintering of AlO-Ni composites in various compositions. The predicted numerical results agree well with the measured thermal and structural properties. The properties predicted by the numerical model are comparable with those obtained using the rules of mixtures and SwiftComp, as well as the Fast Fourier Transform (FFT) based computational homogenization method. The results show that the ABAQUS, SwiftComp and FFT results are fairly close to each other. The effects of porosity and Ni volume fraction on the mechanical and thermal properties are also investigated. It is observed that the mechanical properties and thermal conductivities decrease with the porosity, while the thermal expansion remains unaffected. The proposed integrated modeling and empirical approach could facilitate the development of unique AlO-metal composites with the desired thermal and mechanical properties for ceramic cutting inserts.
对于在不同温度梯度下吸收热冲击的高效切削刀具刀片，需要提高热导率和韧性。此外，热膨胀系数等参数必须保持在合理范围内。这项工作提出了一种基于多尺度建模方法的新型材料设计框架，该框架通过考虑众多复合材料参数，提出了镍（Ni）增强氧化铝（Al₂O₃）复合材料，以定制陶瓷切削刀具所需的机械和热性能。使用DREAM.3D软件程序生成代表性体积单元（RVE），并将输出导入商业有限元软件ABAQUS。包含多个具有不同孔隙率和体积分数的镍颗粒的RVE用于在适当的边界条件（BC）下使用计算均匀化方法预测有效热性能和机械性能。通过烧结各种成分的Al₂O₃-Ni复合材料对RVE框架进行了验证。预测的数值结果与测量的热性能和结构性能吻合良好。数值模型预测的性能与使用混合法则和SwiftComp以及基于快速傅里叶变换（FFT）的计算均匀化方法获得的性能相当。结果表明，ABAQUS、SwiftComp和FFT的结果彼此相当接近。还研究了孔隙率和镍体积分数对机械性能和热性能的影响。观察到机械性能和热导率随孔隙率降低，而热膨胀不受影响。所提出的综合建模和经验方法有助于开发具有陶瓷切削刀片所需热性能和机械性能的独特Al₂O₃基金属复合材料。
