Performance of ceramic tools in high-speed cutting iron-based superalloys

Abstract

ABSTRACTA series of turning tests were conducted to investigate the cutting performance of ceramic tools in high-speed turning iron-based superalloys GH2132 (A286). Three kinds of ceramic tools, KY1540, CC650, and CC670 were used and their materials are Sialon, Al2O3–Ti(C,N), and Al2O3–SiCw, respectively. The cutting forces, cutting temperatures, tool wear morphologies, and tool failure mechanisms are discussed. The experimental results show that with the increase in cutting speed, the resultant cutting forces with KY1540 and CC670 tools show a tendency to increase first and then decrease while those for CC650 increase gradually. The cutting temperature increases monotonically with the increase in cutting speed. The optimum cutting speeds for KY1540 and CC650 when turning GH2132 are less than 100 m/min, while those for CC670 are between 100 and 200 m/min. Flank wear is the main reason that leads to tool failure of KY1540 and CC670 while notch wear is the main factor that leads to tool failure of CC650. Tool failure mechanisms of ceramic tools when machining GH2132 include adhesion, chipping, abrasion, and notching. Better surface roughness can be got using CC670 ceramic tools.