Addition of Nano CaF2@SiO2 and SiC Whiskers in Ceramic Tools for Wear Reduction and Improved Machinability

Abstract

The addition of CaF2@SiO2 and SiC whiskers to ceramic tools can improve their flexural strength and fracture toughness, reduce surface damage, and improve their cutting performance. The cutting experiments showed that under the same cutting conditions, the surface roughness of the workpiece processed with the Al2O3/TiC/SiC/CaF2@SiO2 (ATSC10) tool was significantly lower than that of the workpiece processed with the Al2O3/TiC/ SiC (ATS) tool. Additionally, the main cutting force and cutting temperature when cutting with the ATSC10 tool were lower by 30 and 31.7%, respectively. These results were attributed to the precipitation of CaF2 from the nanocoated particles during cutting and the formation of a uniform and continuous lubricating film on the surface of the tool. The wear on the front surface of the ATS tool was mainly adhesive, and that on the back tool surface was mainly abrasive. For ATSC10, the main forms of wear on the tool front surface were adhesive and abrasive, whereas the main form of wear on the tool back surface was abrasive with slight adhesive wear. The addition of nano-coated particles and whiskers improved the mechanical properties of the cutting tool while maintaining good cutting performance.

Investigation of Cutting Tool Wear in the Milling Process of the Inconel 718 Alloy

“…The values obtained with the D and H parameter sets suggest that when milling with high feed rates of the Inconel 718 alloy, it is necessary to use the highest possible cutting depth values, as this increases the life of the cutting tool and is also economically justified by the volumetric cutting efficiency. The prevalence of whisker-reinforced inserts (CW100), as described in the literature [28], consisting of increased cutting tool life, becomes apparent only when high machining parameters are used. Further analogously, a study of a less frequently used machining method -plunge milling -was conducted.…”

“…Advances in Science and Technology Research Journal 2024, 18(2),[26][27][28][29][30][31][32][33][34][35] …”

Preparation of In Situ Growth Multiscale β-Sialon Grain-Reinforced Al2O3-Based Composite Ceramic Tool Materials

“…In order to process difficult-to-cut materials commonly used in the automobile, aircraft and astronautic manufacturing industries (such as hardened steel, nickel-based and titanium alloys, etc. ), advanced ceramic tools must have high mechanical and thermal properties [ 1 , 2 , 3 , 4 , 5 , 6 ]. For example, at ambient temperature, the flexural strength, fracture toughness, and Vickers hardness of Al 2 O 3 /TiC micro–nano-composite ceramic tool material were 916 MPa, 8.3 MPa·m 1/2 and 18 Gpa, respectively, and still maintained a high flexural strength value (about 390 MPa) at 1200 °C.…”