Wear mechanisms of ceramic cutting tools when machining ferrous and non-ferrous alloys

Performance and wear mechanisms of whisker-reinforced alumina, coated and uncoated PCBN tools when high-speed turning aged Inconel 718

“…wear land closer to the edge. It was pointed by Brandt et al [19] that diffusion of Ni, Cr and Fe into the tool takes place during machining Inconel 718, which leads to degradation of whisker reinforcement. The diffusion rate in the vicinity of the cutting edge is highest since the temperature in the region is highest as well [20].…”

“…8) has revealed that cracks are not superficial and extend deep into the tool bulk. FIB milling of WRA tools have shown that cracks extend only up to 5-10 μm into the tool bulk which are expected to originate during tool cooling at its disengagement [19].…”

Wear mechanisms of silicon carbide-whisker-reinforced alumina (Al2O3–SiCw) cutting tools when high-speed machining aged Alloy 718

“…Notch wear is the dominant wear mechanism which limits tool life of pure alumina ceramics and often leads to tool failure [5]. While application of SiC whisker reinforced or silicon nitride based ceramics may reduce notching, new issues of adhesion [6], diffusion [2] and chemical wear [7] arise.…”

“…Recognized importance draws extensive attention of researchers [1][2][3] where the investigated aspects can be grouped into studies of morphology of worn out tools, chemical stability of tool materials, aspects of strength, etc. Severity of tool wear as a whole depends on the intensity of individual wear mechanisms or their combinations.…”

Augmentation of wear-protective coatings for non-ferrous alloys by the addition of Cr and Ni elements

“…Manufacturing of ceramic-coated non-ferrous alloy components may, in principle, yield benefits over the use of more traditional materials such as ceramics, high-alloy steels and cast iron 1,2 . Certainly, light alloys can offer increased reliability at high loads along with the associated reduction in weight 3 .…”