New observations on wear mechanism of self-reinforced SiAlON ceramic tool in milling of Inconel 718

Self-reinforced SiAlON ceramic tool materials, due to its unique properties such as high wear resistance, high hardness and low affinity with metal, is widely used in machining nickel-based alloy. The self-reinforced SiAlON ceramic tool was used in the experimental process of high speed milling nickel-based alloy Inconel718. The results obtained through observing the tool wear morphology and further analysis showed that when cutting speed vc = 50-200 m/min, abrasive wear and lamellar spalling was the main cause of tool wear. When cutting speed vc = 350, 500 m/min, the bond strength between β-SiAlON whisker and SiAlON matrix reduced, and then the tool material fell off, which led to the formation of hole and groove. When the hole and groove mark connected, the crack nucleation formed. The crack propagation resulted in fracture eventually. At last, according to the tool wear mechanism, tool wear model was established and the optimal cutting temperature range, which can lead to minimum tool wear in milling Inconel718 using self-reinforced SiAlON ceramic tool, was obtained.