Wear patterns and mechanisms of sialon ceramic end-milling tool during high speed machining of nickel-based superalloy

Abstract

In this study, a sialon-based end-milling ceramic tool was utilized to machine nickel-based GH4169 superalloy at a cutting speed of 500 m/min without any cutting fluid, and its wear patterns and wear mechanisms were analyzed by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Results confirmed the application feasibility of machining superalloys by the ceramic-based end-milling tool with high cutting speed. Moreover, flank wear and breakage, including chipping, flaking, and cracking, were found to be the main wear patterns of the ceramic tool. In addition, severe adhesion of superalloy material on the flank face of the ceramic tool occurred during the machining process, resulting in the tool wear. Furthermore, abundant Ni, Fe, and Cr, originating from the GH4169 superalloy were observed on wear regions of the ceramic tool. It can be concluded that the main wear mechanisms of the end-milling ceramic tool were adhesive wear and diffusion wear. Moreover, continuous alternating mechanical load and thermal stress also contributed to the wear and breakage of the ceramic tool.