Machinability experimental study of sintered alumina (Al₂O₃) ceramics material by chemical vapor deposition diamond coating milling tools

Abstract

The sintered alumina (Al 2 O 3 ) ceramic materials featured with high temperature stability, excellent wear resistance, and high strength are highly in demand for various commercial applications. Alumina ceramics in the sintered state are difficult to machine owing to their high hardness. This research focuses on the study on the machinability of sintered alumina ceramic materials by using chemical vapor deposition diamond coating tools. Milling cutting tests are performed on a common 3-axis computer numerical control milling center. Four fluted tungsten carbide end mills with chemical vapor deposition diamond coating are utilized to machine alumina ceramics at different cutting speeds, feed rates, and widths of cut. The cutting process outcome is evaluated based on the machined surface's finish, tool wear and life, the material removal rate, and the cutting force. It is found that the milling machining process for alumina ceramic materials using chemical vapor deposition diamond coating tools is feasible with adequate machining conditions, and the machining outcome largely depends on the cutting conditions. Two alumina ceramics parts are also fabricated to demonstrate the feasibility of proposed machining processes. The details of the machining experiments and the obtained results are presented in this article.

Sustainable Microfabrication Enhancement of Graphene Nanoplatelet-Reinforced Biomedical Alumina Ceramic Matrix Nanocomposites

“…Therefore, there is immense potential in exploring their machining behavior. Several studies have been reported in the literature regarding the machining of pure Al 2 O 3 ceramic [ 36 , 37 ], but studies related to the machining of graphene-based alumina nanocomposites are scarce. As shown in Table 1 , only Sung et al [ 38 ] investigated the electrical discharge machining (EDM) of the graphene-reinforced Al 2 O 3 nanocomposites, while the remaining studies only focused on their characterization.…”

Fabrication of sinusoidal-shaped multi-tip diamond tools by a focused ion beam machining process

“…It is also easy to obtain complex micro/nanostructures by chemical vapor deposition, which is widely used in manufacturing structured tools. 6,7 As a commonly used thermal processing technology for cutting, drilling, machining, etching, welding, and heat treatment, laser processing can process a wide range of materials and shapes. 8 Laser processing has non-contact processing technology characteristics, automation adaptability, low cost, and a small heat-affected zone.…”

Effect of graphite addition on mechanical properties of Al2O3 ceramics by directed laser deposition

“…1,2 Among them, Al 2 O 3 ceramic has the characteristics of small density, high hardness and high temperature stability, and it shows good development potential in the core parts such as high-active cooling components and aeroengine hot-end components. 3–6 At present, Al 2 O 3 ceramic has been used in space shuttle thermal insulation tiles and flexible insulation materials, as well as reinforced metal-based and ceramic-based composite materials, including supersonic jet aircraft nozzles and rocket engine gaskets. 6,7 However, since Al 2 O 3 is a highly brittle material, it is prone to instantaneous brittle fracture during the service process, which seriously restricts its further development in the strategic field.…”