Failure mechanisms of TiB2 particle and SiC whisker reinforced Al2O3 ceramic cutting tools when machining nickel-based alloys

In this paper, Al2O3/TiB2/SiCw ceramic cutting tools with different volume fraction of TiB2 particles and SiC whiskers were produced by hot pressing. The fundamental properties of these composite tool materials were examined. Machining tests with these ceramic tools were carried out on the Inconel718 nickel-based alloys. The tool wear rates and the cutting temperature were measured. The failure mechanisms of these ceramic tools were investigated and correlated to their mechanical properties. Results showed that the fracture toughness and hardness of the composite tool materials continuously increased with increasing SiC whisker content up to 30 vol.%. The relative density decreased with increasing SiC whisker content, the trend of the flexural strength being the same as that of the relative density. Cutting speeds were found to have a profound effect on the wear behaviors of these ceramic tools. The ceramic tools exhibited relative small flank and crater wear at cutting speed lower than 100 m/min, within further increasing of the cutting speed the flank and crater wear increased greatly. Cutting speeds less than 100 m/min were proved to be the best range for this kind of ceramic tool when machining Inconel718 nickel-based alloys. The composite tool materials with higher SiC whisker content showed more wear resistance. Abrasive wear was found to be the predominant flank wear mechanism. While the mechanisms responsible for the crater wear were determined to be adhesion and diffusion due to the high cutting temperature.