Ceramic materials wear mechanisms when cutting nickel-based alloys

Casto, S. Lo; Valvo, Ernesto Lo; Lucchini, E.; Maschio, S.; Piacentini, M.; Ruisi, V.F.

doi:10.1016/s0043-1648(98)00360-3

Cited by 28 publications

(16 citation statements)

References 9 publications

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“…The main wear mechanisms of the ceramic cutting inserts such as abrasion, adhesion, diffusion, plastic deformation, and wear by chemical interaction have been investigated by many [6][7][8][21][22][23][24]. The cutting tools are subjected to high cutting temperatures, high stresses, and complexity experiment.…”

Section: Tool Wear With Different Assisted Technologiesmentioning

confidence: 99%

“…Zhu et al [5] reviewed the tool wear characteristics in machining of nickel-based super alloys. Casto et al [6] noted that the notch wear at the end of cut zone is the main failure when machining Inconel 718 with alumina-zirconia cutting tools, whereas SiC whisker-reinforced alumina ceramic cutting tools exhibit better performance. They also studied the performances of commercial ceramic inserts to traditional carbidebased tool.…”

Section: Introductionmentioning

confidence: 99%

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Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Zhuang

Zhang

Zhu

et al. 2015

Int J Adv Manuf Technol

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This paper is motivated by the fact that machining of Inconel 718 involves rapid tool wear and poor surface integrity. We investigate the performance of ceramic cutting inserts in turning of Inconel 718 by virtue of two different assisted machining conditions, plasma preheating-and cryogenic cooling-assisted technologies. The plasma nozzle placed in front of the cutting zone is used to soften the materials before machining. The liquid nitrogen flow located in the cutting area is used to reduce the cutting temperatures in the contact area. The cutting experiments are set for reducing tool wear and improving surface integrity, including surface roughness and micro-hardness beneath workpiece surface. With these two assisted techniques, the tool wear including flank wear and notch wear and the surface microstructure including surface roughness and micro-hardness are assessed and compared with conventional machining. Tool wear reduction and surface integrity improvement can be obtained with these two assisted technologies in turning of Inconel 718 with ceramic cutting inserts. The main causation of notch wear of the ceramic cutting inserts may be the hardened layer beneath the surface. By comparing these two assisted cutting techniques with opposite effects on the cutting tool and workpiece, it has been found that the surface roughness is reduced by 50 %, the micro-hardness is smaller, and the tool life is extended up to more than 40 % over conventional machining.

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Section: Tool Wear With Different Assisted Technologiesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Zhuang

Zhang

Zhu

et al. 2015

Int J Adv Manuf Technol

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“…9a). Casto et al [12] also observed a similar notch wear on the rake faces of carbide and ceramic tools used to turn AISI 310 steel. In the machining of STAVAX with a hardness of 55 HRC, no sharp ''teeth'' appeared at the edge of the chips (see Fig.…”

Section: Methodsmentioning

confidence: 74%

“…However, most of the work was performed with carbide and ceramic tools [11,12,13]. General assessment of the machined surface was normally obtained by studying the effect of different process parameters and tool wear on the surface finish, waviness and dimensional accuracy.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of machining performance of STAVAX with PCBN tools

Liew

Yuan

Ngoi

2004

The International Journal of Advanced Manufacturing Technology

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A study was undertaken to investigate the wear characteristics of polycrystalline cubic boron nitride (PCBN) cutting tools and surface integrity during machining of STAVAX (specialised stainless steel) with and without coolant. Plastic deformation and formation of overtempered martensite and white layer (untempered martensite) were the dominant subsurface and surface defects. It was found that decreasing the hardness of the STAVAX from 55 HRC to 40 HRC could result in fracture on the flank face, leading to a deterioration of the surface finish. It was observed that low CBN content tools (60%CBN/40%TiN) exhibited greater fracture resistance than high CBN content tools (85%CBN/15%TiN, 90%CBN/10%Co). Although coolant could not bring about a reduction in the flank wear, it was effective in reducing the subsurface and surface defects, and in preventing chipping of the tool edge, leading to an improved surface finish. A superior surface finish (Ra<0.3 μm) was obtained with cutting fluid using a tool with a radius of 0.8 mm, depth of cut of 0.05 mm and feed rate of 0.05 mm/rev.

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“…While it is commonly accepted that plastic deformation for ceramics takes place in superficial zones on the tool [16], bulk plastic deformation in machining is also reported [32,33].…”

Section: Cracking Plastic Deformation and Whisker Degradationmentioning

confidence: 99%

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

Bushlya

Zhou

Avdovic

et al. 2013

Int J Adv Manuf Technol

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Link to publicationCitation for published version (APA): Bushlya, V., Zhou, J., Avdovic, P., & Ståhl, J-E. (2013). Wear mechanisms of silicon carbide-whisker-reinforced alumina (Al2O3-SiCw) cutting tools when high-speed machining aged Alloy 718. International Journal of Advanced Manufacturing Technology, 68(5-8), 1083 -1093 . DOI: 10.1007 General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights.• Users may download and print one copy of any publication from the public portal for the purpose of private study or research.• You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal Bushlya, V., Zhou, J., Avdovic, P., Ståhl, J. AbstractThe paper is aimed on identification and characterization of wear mechanisms of SiC whisker reinforced alumina when turning aged Alloy 718 under different cutting conditions and when machining dry and with coolant. Secondary and back-scatter electron microscopy accompanied by focus ion beam milling and EDX techniques were used for analysis of worn-out tools. Notch wear on the major cutting edge was found to consist of two notches: depth-of-cut notch and secondary notch located outside the chip area. The last was found to be governed by adhesion and attrition associated with adverse chip flow conditions. Formation of minor notch was related to attrition by the defects found on the machined surface. Diffusion of Ni, Fe and Cr into SiC whiskers was found to degrade them and facilitate adhesion. Chemical wear mechanisms were found to be responsible for degradation and decomposition of whiskers and formation of tribolayer on tool surfaces, which in turn was related to the reduced adhesion of Alloy 718 on the tool. Cracking on the tool rake and localized plastic deformation were found to further accelerate tool deterioration.

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Ceramic materials wear mechanisms when cutting nickel-based alloys

Cited by 28 publications

References 9 publications

Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Evaluation of machining performance of STAVAX with PCBN tools

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

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