Strategies for Shaping of Different Ceramic Foams

Rotella, Giovanna; Sanguedolce, Michela; Saffioti, Maria Rosaria; Filice, Luigino; Testa, Flaviano

doi:10.1016/j.promfg.2020.04.345

Cited by 4 publications

(3 citation statements)

References 13 publications

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“…Several studies are referred to conventional and non-conventional machining methods of bulk ceramic materials [9] while there is still a lack of knowledge concerning the machinability of porous ceramic materials. These latter are considered difficult to machine, since they lead to an accelerated tool wear [10], together with a poor final surface quality.…”

Section: Introductionmentioning

confidence: 99%

Milling of alumina-based ceramic foams: tool material effects

Rotella

2023

Theoretical and Applied Mechanics - AIMETA 2022

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Abstract. Porous ceramics are recognized to have the potential to be used for a wide variety of industrial applications, such as catalyst support and molten metal filter. It is a common practice to adjust the shape of ceramics in a pre-sintering stage in order to obtain various configurations but some limitations due to premature failure of the product, marked tool wear or inhomogeneous shrinkage during processing stages may arise, whenever a complex shape is requested. Almost the same happens in the case of post-sintering stage ceramics machining leading, in most cases, to an inefficient process characterized by a severe tool wear and poor final product quality. Such problems, related to tool material, material removal modes and hence process parameters represent a huge limitation for many industrial applications of the above materials. Milling of alumina-based ceramic foams in a sintered state is the focus of the present work. An experimental campaign has been carried out at fixed axial depth of cut, feed rate, number of passes, spindle speed and under flood lubrication regime varying tool material (aluminum oxide-based, diamond-coated). Tool wear mechanisms and final product quality have been investigated through surface analysis in order to verify the workability of alumina based ceramic foams and the related tool wear.

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Section: Introductionmentioning

confidence: 99%

Milling of alumina-based ceramic foams: tool material effects

Rotella

2023

Theoretical and Applied Mechanics - AIMETA 2022

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“…thermal shrinkage, surface quality, resolution), thus it is increasing the use of additive processes in combination with subtractive ones [18]. Processing is often supported by sustainable techniques, such as cryogenic and minimum quantity of lubricant (MQL), allowing to perform machining using a lower amount of cutting fluids to reduce waste and the spread of hazardous substances [19]. Concerning conventional and nonconventional machining methods of bulk ceramic materials [18] many studies were carried out while there is still poor knowledge about the machinability of porous ceramic materials.…”

Section: Introductionmentioning

confidence: 99%

“…Concerning conventional and nonconventional machining methods of bulk ceramic materials [18] many studies were carried out while there is still poor knowledge about the machinability of porous ceramic materials. These latter are considered difficult to machine, since they lead to accelerated tool wear [19], together with poor final surface quality. In fact, they are characterized by a high brittleness combined with the complex lattice shape and porosity, that impact on workability.…”

Section: Introductionmentioning

confidence: 99%

On the impact of tool material and lubrication in ball end milling of ceramic foams

ROTELLA¹

2023

Materials Research Proceedings

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Abstract. High porosity materials, such as ceramic foams, can be used for several applications spanning from thermal insulators, biomedical implants, molten metal filters, and others. The general practice is to adjust the shape of those ceramic foams in a pre-sintering stage to obtain complex shapes. This work aims to investigate the workability of ceramic foams in a post-sintering condition as an alternative way to overcome premature product failure during production and inhomogeneous shrinkage during sintering. An experimental campaign of ball end milling of alumina-based ceramic foams in a sintered state was carried out herein. Two different tool materials (aluminum oxide-based, diamond-coated) have been tested using two levels of spindle speed under minimum quantity lubrication (MQL) and flood lubrication regimes. The most important findings are: (i) the influence of lubricant is more pronounced analyzing the tool wear, but it has a smaller effect on surface characteristics of the workpiece, (ii) higher spindle speed improves workpiece surface quality (ii) diamond coated tools are the best available choice in terms of both tool wear and surface quality.

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