Interrupted hard turning performance of ceramic cutting tools possessing microscopic geometries established with the two-dimensional fluid-like characteristics of the chip considered

Abstract

Interrupted hard turning performance of ceramic tools with varying microscopic geometries on the rake face was analyzed. A new performance index Gma was proposed for the ceramic tools. Both the external loads and the micromechanical properties of the tool material were incorporated in the proposed tool performance index. Quantitative analysis was conducted to reveal the two-dimensional fluid-like characteristics of the chip. Different kinds of microscopic textures such as MA, MB, MC, and MD were created on the rake face for ceramic tools considering the analysis results. Based on the tool performance index, performance of ceramic cutting tools which had varying microscopic textures were pre-evaluated for different groups of cutting speeds and cutting length ratios. Experimental tool lives were acquired to demonstrate the tool performance index and identify the optimum tool surface microscopic geometry. It was found that the tool performance index can be utilized to effectively pre-evaluate tool performance. Microscopic textures MB, MC, and MD were more efficient for tool life extension at relatively small cutting length ratio and relatively large cutting speed. Due to the consideration of the two-dimensional fluid-like characteristics of the chip in the design process, microscopic texture MD exhibited the highest efficiency in the tool performance enhancement.