复合超微钻头材料制备与微挤压成形机制

With the rapid development of electronic and information industries based on Printed Circuit Board (PCB), PCB CNC drilling sizes are getting smaller with the trend toward miniaturization. Therefore, it is urgent necessary to reduce the material cost of micro drills and improve micro drill material manufacturing process, and then increase its hardness, wear resistance and fracture toughnesso as well..This project focuses on the preparation of composite micro drill material with solid carbide and solid steel core based on the combination of powder metallurgy and micro extrusion. For the metal micro extrusion process characterization and present challenges, systematic research will be conducted to investigate the microstructure evolution behavior in micro-extrusion process, and the influence of size effect on deformation characterization of advanced composite material in terms of metal micro-scale plasticity, micro surface tribology and lubrication, metal microstructure evolution theory, finite element analysis and precision micro-nano machinery designing and manufacturing. The proposed project aims to set up finite element modelling on the powder metallurgy and micro extrusion process, considering size effect, tribology and lubrication, and surface properties of composite material, and also to systemically develop numerical simulation platform including composite material preparation, die designing, compound micro extrusion process and drill flute manufacturing and designing. The research will enhance bonding mechanism and forming mechanism in preparing composite micro material where the powder metallurgy is combined with micro extrusion forming, break through the size effect limit on micro extrusion, and construct micro plastic forming theory of composite material.

随着以印刷电路板为基础的信息产业的高速发展，电路板的制板孔尺寸越来越小，迫切要求印制板孔的微型钻头材料相应的提高硬度、耐磨性和断裂韧性，并改进加工方法，降低加工成本。本项目以粉末冶金和微挤压成形相结合的方式制备新型“硬质合金+固体钢芯”复合微钻头材料，针对微尺度下金属挤压成形工艺特点和面临问题，结合粉末冶金机理、金属微成形塑性力学、微观表面摩擦与润滑学、材料微观组织演变理论、有限元分析方法和精密微纳机械设计制造技术，阐明微尺度下挤压成形过程组织演变规律、摩擦效应与尺寸效应对新型复合材料成形特性的影响，建立考虑尺寸效应、摩擦效应及表面性能的粉末冶金和微挤压成形过程的有限元模型，开发包括复合材料制备、模具设计、微挤压成形过程和钻槽加工设计的数值模拟仿真平台。本项目旨在揭示微尺度下新型微钻头材料的制备与成形机制，突破尺寸效应对微挤压成形造成的限制，构建复合材料微成形基础理论体系。

由于电子工业及精密机械的飞速发展，微成形技术已成为工业领域的主流发展方向之一。随着以印刷电路板为基础的信息产业的高速发展，电路板的制板孔尺寸越来越小，迫切要求印制板孔的微型钻头材料相应的提高硬度、耐磨性和断裂韧性，并改进加工方法，降低加工成本。. 本项目以粉末冶金和微挤压成形相结合的方式制备新型“硬质合金+固体钢芯”复合微钻头材料，针对微尺度下金属挤压成形工艺特点和面临问题，结合粉末冶金机理、金属微成形塑性力学、微观表面摩擦与润滑学、材料微观组织演变理论、有限元分析方法和精密微纳机械设计制造技术，阐明微尺度下挤压成形过程组织演变规律、摩擦效应与尺寸效应对新型复合材料成形特性的影响。通过控制工艺参数，分析微尺度下复合材料在挤压成形阶段组织演变规律和尺寸效应对新型复合材料成形特性的响，明确微挤压条件下的热压粉末烧结、粉末和固体界面的复合机理。本项目旨在揭示微尺度下新型微钻头材料的制备与成形机制，突破尺寸效应对微挤压成形造成的限制，构建复合材料微成形基础理论体系。通过本课题研究可以进一步降低微钻头的制造成本，使用更少的硬质合金，并且满足微钻头材料行业不断提高的产量和性能要求，从而研制开发初具有优良性能的复合微型钻头材料及其先进的微成形技术，这种新材料制备及其微成形技术会不断丰富国际先进制造业的基础理论。