Wear mechanisms and residual stresses in alumina-based laminated cutting tools

Abstract The outstanding performances of the Al2O3 cutting tools in terms of potential cutting speed can lead to substantial economies in the machining of metallic materials. Nevertheless, their widespread use is limited by some drawbacks such as the tendency to edge chipping and to the propagation of microcracks, which can lead to premature failures. These shortcomings are due to the intrinsic low toughness of the ceramic material, which is in turn related to its characteristics non-metallic bonds. A well-recognised method of increasing the toughness of brittle materials is the introduction of surface compressive stresses, which can be obtained through a suitable lamination geometry of the…

Wear rates and wear mechanisms of alumina-based tools cutting steel at a low cutting speed

Abstract Three ceramic insert materials, zirconia-toughened alumina (Al 2 O 3 –7vol%ZrO 2 ), mixed-based alumina (Al 2 O 3 –TiN–TiC–ZrO 2 ) and alumina reinforced with SiC whiskers (Al 2 O 3 –SiC w ), were used to cut AISI 1040 steel at 3.9 m s −1 . In addition, a traditional grade P10 insert (WC–TiC–Co) was tested. The lifetimes, according to KT/KM and VB B criteria, were determined using a profilometer and by image processing. The worn zones were observed with scanning electron microscopy techniques. Adhesion and plastic deformation were dominant wear mechanisms in zirconia-toughened alumina, mixed-based alumina and sintered carbide P10, both in the craters and in the cutting edges. As we…

Ceramic materials wear mechanisms when cutting nickel-based alloys

Abstract In this paper the performances of some commercial ceramic inserts when cutting AISI 310 steel are investigated and compared to those of a traditional carbide based tool. The most important wear mechanism in the ceramic inserts is related to the segmented edges of the chips that abrade a notch at the end of the cut zone. Alumina–zirconia inserts are very sensitive to this kind of wear, whereas tools made of Sialon and alumina with SiC whiskers exhibit slightly better performances despite the concomitant chemical wear mechanisms.

Performances of Three Layered Ceramic Composites Inserts for Steel Cutting

Sandwich-structured three-layered ceramic inserts were made with the aim of obtaining ceramic cutting tools with an increased useful life.

Cutting Temperatures Evaluation in Ceramic Tools: Experimental Tests, Numerical Analysis and SEM Observations

The authors propose a multiple approach for the evaluation of cutting temperatures in ceramic tools. The first approach was the experimental evaluation of equitemperature lines, obtained in three-dimensional cutting by employing constant melting point powders scattered on planes parallel to rake face. In the second approach, a numerical finite element analysis was performed. At this step the determination of the percentage of total heat produced in the operation that flows into the tool was considered and, consequently, the temperature distribution within the whole volume of the insert. Finally, the examination of the crater zone with SEM microscopy confirmed the temperature levels as previ…

Machining of Steel with Advanced Ceramic Cutting-Tools