Cutting performance and life prediction of an Al2O3/TiC micro–nano-composite ceramic tool when machining austenitic stainless steel

The cutting performance and failure modes of an Al2O3/TiC micro–nano-composite ceramic tool in the machining of austenitic stainless steel were investigated. Orthogonal test and range analysis were employed to determine the optimal cutting parameters. The largest metal removal amount was got at the speed of 80 m/min, the feed rate of 0.15 mm/r and the depth of cut of 0.1 mm. The wear resistance of Al2O3/TiC micro–nano-composite ceramic tool were better than that of the alumina-based ceramic tool only reinforced by micro-scale TiC particles. Failure modes of the present tool were cutting edge fracture and tool material peeling off, which mainly resulted from the subcritical crack growth in the tool. The ceramic tool life was predicted based on the dynamic fatigue behavior of the tool material. Due to the inherent fatigue behavior of ceramics, the tensile stress distributing in ceramic tool would cause cracks initiation and promote the cracks extension. The life of ceramic tool for the failure mode of breakage was closely related to the fatigue behavior of the tool material. So, the ceramic tool life could be predicted by calculating the fatigue life of tool material. The stochastic tool life well scattered in the tool life prediction interval.