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(MPa) fracture toughness
(MPa·m1â„2) Hardness
(GPa) Al2O3/SiC/(W,Ti)C(ASW) 753 5.32 19.07 Al2O3/SiC(AS) 671 5.15 18.81 Al2O3/(W,Ti)C(AT) 765 5.19 18.92 
(a) 
(b) Fig. 1 Curve of flank wear when cutting cast iron under different cutting conditions 
Fig. 2 Abrasion profile of the flank of ASW ceramic tool at low speed cutting of cast iron 
(a) 
(b) Figure 3 Wear profile of ASW ceramic tool during high speed cutting of cast iron. 2 Test conditions The cutting test was carried out on a CA6140 machine tool. The workpiece material was grey cast iron HT300 with a hardness of 200-250 HB. The tool material used is Al2O3/SiC/(W,Ti)C multi-phase composite ceramic tool material, represented by ASW. In order to facilitate the comparative analysis, Al2O3/SiC and Al2O3/(W,Ti)C two-phase composite ceramic cutting tool materials were used at the same time, and expressed as AS and AT respectively. The tool geometry is g0=-5°, a0=5°, ls=-5°, kr=75°, bg1×g01=0.2mm×(-20°), re=0.6mm. The microstructure of the tool wear surface was observed on a HITACHIS-570 scanning electron microscope. The mechanical properties of several ceramic tool materials are shown in the table. 3 Wear characteristics Fig. 1a shows the flank wear curves of several ceramic tool materials when cutting gray cast iron under the conditions of v = 100m/min, f = 0.2mm/r, and ap = 5.0mm. It can be seen that several ceramic tool materials have good wear resistance, among which ASW tool is the best and AT tool is the second, while SiC-only alumina ceramic tool material AS has the worst wear resistance. Under the experimental conditions, the flank wear of several ceramic tool materials is relatively uniform, and the wear curves are in good agreement with the wear law. In contrast, several ceramic tool materials wear at higher cutting speeds and smaller depths of cut (v=230 m/min, f=0.2 mm/r, ap=2.5 mm) (Fig. 1b). Although the law is similar to this, the wear properties are different. According to the pros and cons of the flank wear performance, the order is AT better than ASW than AS. Relatively speaking, the difference in composition has a more pronounced effect on the wear resistance of the material. In addition, as can also be seen in comparison with FIGS. 1 a and 1 b , under the latter cutting conditions, the amount of flank wear of the corresponding tool material at the same time of cutting is greater. With different tool materials, the amount of wear increases. For ASW ceramic tool material, the maximum flank wear under both cutting conditions in Figures 1a and 1b increased from 0.28mm to 0.40mm. For AS and AT ceramic tool materials, they increased from 0.36mm and 0.31mm to 0.52mm and 0.35mm, respectively. 4 wear mechanism Ceramic cutting tools in the low-speed cutting of the tool wear in the form of rake face and flank wear, the main wear mechanism is wear. Studies have shown that for ceramics and other brittle materials, which are mainly based on abrasive wear, their wear resistance is proportional to KIC3â„4H1â„2. The higher the fracture toughness KIC, the higher the hardness H, the higher the wear resistance of the material. As can be seen from the above table, the fracture toughness and hardness of ASW ceramic tool materials are higher than those of the other two tool materials AS and AT, so the wear resistance is best. On the other hand, when cutting cast iron at a low speed, because the cutting temperature is low, SiC inside the material does not react with Fe chemically, and SiC itself does not oxidize or oxidize very weakly. At this time, the proportion of adhesive wear, chemical reaction and oxidative wear is small, so SiC and ASW ceramic cutting tool materials exhibit good wear resistance. Figure 2 shows the SEM appearance of the flank wear of the ASW ceramic tool material. From this, noticeable signs of abrasive wear can be found, and the bond is very slight. However, at high cutting speeds, although the wear patterns of the tool are mostly wear of the former surface and the flank surface, the adhesion phenomenon in the wear area of ​​the rake surface is greatly increased. Figure 3a shows the rake face wear profile of the ASW ceramic tool material. Due to the high temperature effect during cutting, the tendency of SiC and Fe to undergo a chemical reaction increases, and the adhesion wear increases. On the other hand, dissolution wear occurs at high temperatures. It was found that the solubility of Fe in SiC is higher by about 2 orders of magnitude or more than that in TiC or the like at high temperature. Therefore, due to the chemical reaction of Fe and SiC and their mutual dissolution, the content of Fe in the tool increases. This will increase the tendency of the tool to adhere to the workpiece material and will therefore be detrimental to the wear resistance of the tool. Similarly, the increase in flank adhesion has also demonstrated this (Figure 3b). In fact, ceramic cutting tool materials containing SiC all have this problem when high-speed machining of iron-based workpiece materials. Therefore, care must be taken when selecting tool materials. It can be considered to be used in rough machining processes such as low-speed large depth of cut, or in the processing of nickel-based alloys, because SiC-containing ceramic cutting tool materials exhibit good cutting performance when cutting pure nickel or nickel-based alloys. In addition, the compatibility of the workpiece material and the tool material can be taken into account when designing the new ceramic tool material, so that the tool material specifically used for processing a certain type or several types of workpiece materials can be manufactured in a targeted manner. To address this issue, follow-up studies are ongoing.
Study on Wear Performance of New Ceramic Tool Materials
1 Introduction Modern ceramic tool materials are one of the most promising tool materials for the 21st century. It has been developed from the earliest pure Al2O3 ceramics to the addition of various oxides, nitrides, carbides and borides such as TiC, TiN, TiB2, SiC, (W, Ti)C, Ti(C,N), WC and ZrO2 and other multi-phase ceramic tool materials, and in the performance of materials and applications, and many other areas have made great progress. At the same time, it should also be noted that the actual application range of domestic ceramic tool materials is still limited, and there is still a certain gap between the research on the types of materials, properties, and applications, etc., and the relevant research remains to be in-depth. Recent studies have shown that multi-phase composite ceramic materials are one of the three major trends in the future of advanced structural ceramic materials. Similarly, the development of ceramic materials in the direction of multi-phase compounding has provided broader scope for the design, manufacture and application of ceramic tool materials. Based on the new multi-phase composite ceramic tool material Al2O3/SiC/(W,Ti)C developed by the author, the wear properties and wear mechanism of the tool material in the machining of cast iron were studied in detail. The promotion and application laid a good foundation. Comparison of mechanical properties of several ceramic tool materials Tool material bending strength