Research on High Performance Milling of Engineering Ceramics from the Perspective of Cutting Variables Setting

Abstract

The setting of cutting variables for precision milling of ceramics is important to both the machined surface quality and material removal rate (MRR). This work specifically aims at the performance of corner radius PCD (polycrystalline diamond) end mill in precision milling of zirconia ceramics with relatively big cutting parameters. The characteristics of the cutting zone in precision milling ceramics with corner radius end mill are analyzed. The relationships between the maximum uncut chip thickness (hmax) and the milling parameters including feed per tooth (fz), axial depth of cut (ap) and tool corner radius (rε) are discussed. Precision milling experiments with exploratory milling parameters that cause uncut chip thickness larger than the critical value were carried out. The material removal mechanism was also analyzed. According to the results, it is advisable to increase fz appropriately during precision milling ZrO2 ceramics with corner radius end mill. There is still a chance to obtain ductile processed surface, as long as the brittle failure area is controlled within a certain range. The appropriate increasing of ap, not only can prevent the brittle damage from affecting the machined surface, but also could increase the MRR. The milling force increases with increasing MRR, but the surface roughness can still be stabilized within a certain range.

Feasibility of Cobalt-Free Nanostructured WC Cutting Inserts for Machining of a TiC/Fe Composite

“…In the case of typical difficult-to-cut materials, keeping high machined surface quality and improving machining efficiency has always been a key issue [ 28 ]. Considerable efforts have been made to improve the cutting performance of carbide tools in conditions without cooling and lubricating fluids and at elevated cutting speeds, when the carbide tool is subjected to more severe friction and wear, leading to the reduction of service life [ 29 ].…”

Synergic Influence of River Gravels and Crushed Aggregates on the Mechanical Properties of Concrete

“…River gravel can also be used in concrete and is used in concrete but of non-standard strength as there is still no standard for river gravel for its use in concrete in civil engineering work. As river gravel is very cheap to source so, if the goal is to reduce the cost of construction it can be used in places like walkways or places where no heavy loads of structure are applied [21].…”

Technological principles for removal of defective surface layer on grinded ceramic products by etching with accelerated argon

“…Various studies have shown that defects formed at various stages of manufacturing ceramic parts and tools (hot sintering of workpieces and diamond sharpening) increase the probability of brittle fracture and hinder the industrial use of ceramics [4][5][6]. In addition, the presence of a defective layer can limit the functional characteristics of various coatings, the deposition of which is often used as a finishing operation in the technological process of ceramic products' manufacturing for the needs of mechanical engineering [7][8][9][10].…”