Comparative Analysis on the Wear Performance of New and Reconditioned Ceramic Cutting Tools When Machining Nodular Cast Iron GGG-60, with Lubrication of Two Types of Fluids

Abstract

The advantages and disadvantages of reusing machining tools were evaluated in this research, because through the monitoring of insert wear it was possible to compare the performance between the new and reconditioned tools when machining nodular cast iron GGG-60. In this way, the material was milled with a new tool, reconditioned tool with SiAlON, silicon nitride based ceramic insert. In the study, two cutting parameters were considered, one recommended by the tool manufacturer and the other optimized during pretests. Aiming at a sustainable process, a semi-synthetic soluble mineral oil and a vegetable oil were used as the cutting fluid for the study. Thus, through the Action 6.0 software, a complete factorial experimental design was carried out, in three independent variables and two levels, observing the tool life and the wear mechanisms in the response. Therefore, it was observed that the main mechanism of abrasion and adhesion wear, both for the new tool and the reconditioned one, generated a noticeable flank wear. However, the best statistically obtained interaction for the process variables was found for new tools in cutting parameter P1 and semi-synthetic Rocol Ultracut cutting fluid.