WEAR OF CERAMIC CUTTING TOOLS IN NI-BASED SUPERALLOY MACHINING

The machining performance of monolithic and composite silicon nitride and Al2O3phased cutting tools in continuous turning of Inconel 718 was examined. The character of tool wear has been found to vary, depending on the feed rate and cutting speeds. At a. lower cutting speed of 120 ml min, tool life is restricted by depth-of-cut notching, while at high cutting speeds (300 m/min), tools fail due to nose wear and. fracture. The sensitivity of monolithic Si3N4and Al2O3to depth-of-cut notching was found to be significantly reduced with the addition of SiC whiskers, and to a lesser extent with Ti-C particulates. The ceramic composites also exhibited resistance to nose and flank wear that was higher than that of the monoliths. The internal stress distribution for the cutting tool has been calculated using the finite element method and is the basis for explaining fracture beneath the rake face. Cutting tool wear results are discussed in terms of chemical and mechanical properties of the ceramic tool material, abrasive wear, thermal shock resistance, and metal cutting conditions. © 1990 Taylor & Francis Group, LLC.