Injection molding of ceramic cutting tools for wood-based materials

In this study a mutable mold for ceramic cutting tools with inserts of different cutting angles and two different injection positions was designed. Three alumina-based ceramic feedstocks with different types and amount of second phases were developed. A mold filling study was carried out for both sprue positions in order to prove the molding behavior of the feedstock and the functionality of the mold. Debindering and sintering of molded green parts was arranged for each composition, respectively. Mechanical properties, microstructure and achieved cutting edge sharpness of produced tools were investigated. Results show that the mold design and injection molding process play a key role in order to manufacture cutting tools of best possible sharpness enabling a wood machining process. Feedstocks exhibit a good mold filling behavior resulting in comparatively sharp cutting edges of ≈10 μm after sintering. Mechanical properties show high potential for application of wood machining cutting tools.