Experimental study on the cutting performance of microwave sintered Al2O3/TiC ceramic tool in the machining of hardened steel

• Al2O3/TiC ceramic tool (AT33) materials were fabricated by microwave sintering.
• Cutting performance of three tools was investigated in machining of hardened steel.
• AT33 inserts showed better cutting performance.
• Wear mechanisms of AT33 insert were investigated.
• The densification can be promoted by microwave sintering.

An Al2O3/TiC composite ceramic tool material was fabricated by microwave sintering. The cutting performance was experimentally studied when machining hardened alloy steel 40Cr (50 ± 2HRC) and hardened tool steel T10A (60 ± 2HRC), in comparison with those of an Al2O3/TiC ceramic tool (LT55) produced by hot-pressing technology and a WC/Co cemented carbide tool (YS8). Stereomicroscope, scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) were applied for the measurements of flank wear value, observations of tool faces and analyses of elements deposited on tool faces. The results showed that AT33 had much longer tool life than that of LT55 and YS8 when machining hardened steel 40Cr at any given cutting speeds. In the case of machining hardened steel T10A, AT33 exhibited better cutting performance than that of LT55 at the lower cutting speed (69 m/min, 104 m/min). Wear mechanisms of Al2O3/TiC ceramic tool AT33 were mainly abrasion and adhesion.