Determining the influence of ultra-dispersed aluminum nitride impurities on the structure and physical-mechanical properties of tool ceramics (original) (raw)
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Machinability of Aluminum Nitride Ceramic Using TiAlN and TiN Coated Carbide Tool Insert
Materials Science Forum, 2013
This research presents the performance of Aluminum nitride ceramic in end milling using using TiAlN and TiN coated carbide tool insert under dry machining. The surface roughness of the work piece and tool wear was analyzed in this. The design of experiments (DOE) approach using Response surface methodology was implemented to optimize the cutting parameters of a computer numerical control (CNC) end milling machine. The analysis of variance (ANOVA) was adapted to identify the most influential factors on the CNC end milling process. The mathematical predictive model developed for surface roughness and tool wear in terms of cutting speed, feed rate, and depth of cut. The cutting speed is found to be the most significant factor affecting the surface roughness of work piece and tool wear in end milling process.
Development of Cutting Force Model of Aluminum Nitride Ceramic Processed by Micro End Milling
Applied Mechanics and Materials, 2011
Advanced ceramics are difficult to do machining due to brittle nature. High cutting forces will generate in the machining, which will affect the surface integrity of final product. Selection of proper machining parameters is important to obtain less cutting force. The present work deals with the study and development of a cutting force prediction model in end milling operation of Aluminum Nitride ceramic. The cutting force equation developed using Response Surface Methodology (RSM) to analyze the effect of Spindle speed, feed rate and axial depth of cut. The cutting tests were carried under dry condition using two flute square end micro grain carbide end mills.
High-speed machining of aerospace alloys can be enhanced by the use of advanced cutting tool materials such as nano-grain size ceramics that exhibit improved physical and mechanical properties than their micron grain counterparts. The performance of recently developed nano-grain size ceramic tool materials were evaluated when machining nickel base, Inconel 718, in terms of tool life, tool failure modes and wear mechanisms as well as component forces generated under different roughing conditions. The tools were rejected mainly due to wear on the tool nose. It is also evident that chemical compositions of the tool materials played significant role in their failure. The alumina base ceramics performed better than the silicon nitride base ceramics. Severe abrasion wear was observed on both rake and flank faces of the cutting tools while cutting forces increased with increasing cutting speed when machining with the silicon nitride base nano-ceramic tools. This is probably due to the lower superplastic flow temperature of the nitride base nano-ceramics. The alumina base ceramics are more susceptible to chipping at the cutting edge than the silicon nitride base ceramics despite their higher edge toughness.
Ultradispersed nitride powder-base ceramic tool materials
Soviet Powder Metallurgy and Metal Ceramics, 1990
The tendency toward an increase in the portion of ceramic tool materials in the total amount of metal working toois is the result of development of new materials, the increase in the share of final and finishing operations, the wide use of heat treatment of machine parts, and the increase in labor productivity. Therefore the development of new materials based on inexpensive and readily available refractory compounds is a very pressing problem [1-3]. An analysis of the basic directions in investigation and development of ceramic materials showed that one of the most promising means is use as the base of silicon nitride and sialons in place of the traditionally used aluminum oxide and titanium carbide [4, 5]. investigation of the phase composition, structure, and properties of these materials made it possible to improve the production method for nonresharpenabie tips [6, 7].
Performance of alumina-based ceramic inserts in high-speed machining of nimonic 80A
Materials and Manufacturing Processes, 2018
The study of machining forces and cutting tool wear during the machining is important for designing and selection of machining system and improving the productivity. This study reports the machinability of Nimonic 80A superalloy with alumina-based ceramic inserts. The objective is to analyze the reason for higher cutting forces generated during machining and tool wear mechanism on machining parameters. The cutting forces and tool wear are found to be mainly influenced by the cutting speed. The main causes of tool failure while machining Nimonic 80A are adhesion and abrasion. The role of tool wear is more dominant on the surface finish at lower cutting speed. Also, with an increase in cutting speed, thermally activated wear quietly increases at tool surfaces. The mechanistic approach is used to model the main cutting force. Developed cutting force model agrees well with experimental cutting force values.
Effect of Yttrium and Rhenium Ion Implantation on the Performance of Nitride Ceramic Cutting Tools
Materials, 2020
In the paper, the results of experimental investigations of ion implanted cutting tools performance are presented. The tools, made out of Si3N4 with additives typically used for turning of Ti-6Al-4V alloy, underwent implantation with ions of yttrium (Y+) and rhenium (Re+) using the metal vapor vacuum arc method. Distribution of ions on the tool surface was measured. The cutting tools were tested in turning process with measurement of cutting forces and analysis of wear. A rather unexpected result was the increased wear of the tool after Y+ implantation with 1 × 1017 ion/cm2. It was demonstrated, however, that the tool after Y+ 2 × 1017 ion/cm2 ion implantation provided the best machining performance.
Handbook of Advanced Ceramics Machining
2006
Ceramics is one of the primary fields in which improvements in processing and advanced products can be anticipated. Such products have an increased technological knowledge content and have to be manufactured using processing technology that is more advanced and better controlled. Advancements in ceramic machining and manufacturing technology are necessary for the commercialization of new processing technology; these innovations may lead to eliminating expensive steps, improving productivity, and increasing product reliability. Most of the industrialized countries of the world have invested heavily in the manufacturing (processing) of new ceramic materials, which led to the production of lower-priced ceramics with better properties. This successful development is useful, but is not good enough for the anticipated boom in the ceramic materials industry. The main problem in the use of ceramics is that machining is still very expensive. This prohibits the replacement of metal parts with ceramic parts in nearly all industries in which machined parts are used, such as the automotive, aerospace, and semiconductor industries. This book presents the latest developments in machining of advanced ceramics. Most of the authors have dedicated their whole lives to the study of ceramic machining and ceramic stock removal mechanisms. Ductile grinding of ceramics is the focus of Chapter 1 by Professor Eda of Ibaraki University in Japan. His laboratory is well known mainly for new methods and tools for machining of ceramics and other semiconductor materials. Chapter 2 comes from Kumamoto University. Over the years, Professors Yasui and Matsuo developed special techniques for grinding fine ceramics using diamond wheels with coarse grains. Chapter 3 deals with fundamentals: mechanisms for grinding of ceramics. Professor Malkin, considered a ''guru'' in grinding of ceramics and general grinding, spent many years investigating different aspects of the grinding of ceramics. This chapter is a kind of summary of his findings. Chapter 4 focuses on the correlation between grinding parameters and the strength and depth of mechanical damage. Professor Mayer of the University of Texas spent most of his life investigating these phenomena. Chapter 5, Chapter 6, Chapter 9, and Chapter 15 present a new technology: electrolytic in-process dressing (ELID) grinding of ceramics, which was developed in Japan by Professor Nakagawa and his student Dr. Ohmori, who is coauthor of three of the chapters dedicated to ELID technologies. The other authors spent long periods of time working with Dr. Ohmori and his team at the Japan Institute for Physical and Chemical Research (RIKEN) in Tokyo. ELID is one of the most promising technologies for machining of ceramics, especially for high accuracy and mirror-like surfaces. I would like to mention three very young coauthors of these chapters: Dr. Katahira, Dr. Kato, and Dr. Spanu, who finished his doctoral thesis on this subject two years ago. The authors of this chapter represent three generations of researchers working on this promising technology. Chapter 7 was written by a team from the Precision Micro-Machining Center of the University of Toledo, Ohio. The chapter presents a method that is new and not very familiar to the industry: belt centerless grinding of ceramics materials using special diamond belts. This method is used mainly for high-efficiency grinding applications where the main objective is the stock removal rate and the second objective is the quality of the surface. Chapter 8 also comes from the Precision Micro-Machining Center and presents a modern technique for monitoring the ceramic lapping process: acoustic emission (AE). AE is well known as a tool to monitor the ceramic grinding process; however, there are only a few studies regarding AE in the lapping process. Chapter 10 was written by a team of academic and industrial researchers: Mariana Pruteanu, Ion Benea, and myself. The chapter presents a study dealing with the lapping of ceramics with diamond slurry and it emphasizes the differences between mono-and polycrystalline diamond. Chapter 11 is one of the chapters with emphasis on fundamentals and presents an original model for lapping of ceramics: the double fracture model. I developed this model with my students over the past fifteen years, trying to provide a more complex material removal model in the case of lapping of ceramics (indentation and scratch). Chapter 12 looks at a method to replace lapping (double lapping) of ceramics with grinding (double grinding) using the same kinematics. Written by Dr. Christian Spanu, Dr. Mike Hitchiner, and myself, this chapter discusses the state of the art for this technology, which is gaining more ground every day. Chapter 13 focuses on the nanomachining of ceramic materials, mainly through super polishing, a technology developed in principle for the semiconductor industry. The work was done at the Precision Micro-Machining Center and uses a state-of-the-art super-polishing machine with a special technology for AlTiC magnetic heads. The quality of the surface obtained is at the level of 2-5 Å. Chapter 14 discusses a new technology that has never been used in industry: laser-assisted grinding of ceramics. I developed this technology with Dr. Howes and Dr. Webster at the University of Connecticut in the early 1990s. New developments show that this is a promising technology, which may allow grinding of ceramics with high productivity and high accuracy at the same time. Chapter 16 and Chapter 17 come from the Fraunhofer Institute of Berlin, one of the best machining laboratories in Germany, with an old tradition in machining of ceramics. Developed by senior Professor Spur and his successor, Professor Uhlmann, one chapter is dedicated to the ultrasonic grinding of ceramics, a technology successfully developed in Berlin; the second is a summary of the findings of the latest research in different grinding methods of ceramic materials. This book is addressed to a broad category of people: engineers and technicians in industry; students; and researchers and scientists in government research institutions. With new alternative fuels and energy on the horizon, ceramic materials are feasible alternative engine materials, able to work at high temperature with minimum wear. I would like to thank all my coauthors and contributors for taking the time to prepare the manuscript. I would also like to thank my wife Jocelyn for putting up with my long hours of work and with very short weekends. Without their help and encouragement, this book would not have been possible.
Performance Studies of Alumina TiC-based Ceramic Tool Inserts when Turning Tool Steels
Investigation in this paper is devoted to evaluating the cutting performance of two alumina TiC-based ceramic cutting tools having negative side cutting edge angles (SCEA)s of -5 0 (CNG) and -1 0 (TNG) by finish turning two tool steels. Experimental studies were carried out at various cutting speeds, feeds and depths of cut in dry conditions. The cutting performance of the alumina-based ceramic tools was judged by the cutting force produced during the process of machining and by the surface roughness of the workpieces. The influence of the cutting parameters (that is, the cutting speed, feed and depth of cut) on the cutting performance is discussed. The higher negative SCEA of -5 0 generally works better for the tool steels than the -1 0 . Turning with ceramics compares favourably with alternative machining processes normally used in the fabrication of die and moulds.
Proceedings of The Institution of Mechanical Engineers Part B-journal of Engineering Manufacture, 2005
Alumina-based mixed ceramic (CC650) and cubic boron nitride-based (CBN) (CBN7020) tools are becoming mostly preferred for machining under severe conditions. The aim of this study is to investigate the effect of cutting parameters on ceramic and CBN tool wear in the hard turning of X200Cr12 steel. The results indicate that the comparison span for both tool materials is limited to a speed of 180 m/min at which catastrophic ceramic cutting edge collapse took place. The tool life ratio rose from 4.37 to 17.14 when the cutting speed evolved from 90 to 180 m/min in favour of CBN which resisted up to a cutting speed of 350 m/min. The feed rate effect on roughness (mm) is satisfactorily predicted by a power model deduced from experimental data and is compared with a theoretical model. A correlation between surface roughness and tool wear is proposed for the usual cutting speed ranges and for the two tested inserts respectively. The analysis also revealed that, under the allowable wear limit, the ceramic tool gave quality surfaces with higher roughness than the CBN tool. In conclusion this work highlights that 120 m/min is the optimal cutting speed value for machining X200Cr12 using CBN7020 while 60 m/min is the optimal cutting speed value for CC650 steel.