Title: Fabrication and cutting performance of an Al₂O₃-(W, Ti)C functionally gradient ceramic tools

Authors: Jun Zhao, Xing Ai

Addresses: School of Mechanical Engineering, Shandong University, Jinan 250061, Shandong Province, PR China. ' School of Mechanical Engineering, Shandong University, Jinan 250061, Shandong Province, PR China

Abstract: According to the design rules for Functionally Gradient Materials (FGM) with high thermal shock resistance proposed in the previous work of the author, an Al₂O₃-(W, Ti)C FGM ceramic tool material with symmetrically laminated structure was fabricated by using hot-pressing technique. The cutting performance, failure modes and mechanisms of the FGM ceramic tool were investigated via intermittent cutting experiments in comparison with those of a common homogeneous Al₂O₃-(W, Ti)C ceramic tool. The results revealed an improved tool live of the FGM tool over that of the homogeneous ceramic tool. The FGM tool exhibited similar chipping characteristics and failure modes to that of the homogeneous ceramic tools at a lower cutting speed, but different failure modes from that of the homogeneous ceramic tool at higher cutting speeds. The failure of the homogeneous ceramic tool at higher cutting speeds was mainly caused by plastic deformation and thermal shock, whereas the failure mechanisms of the FGM tool were mainly the mechanically induced wear and mechanical fatigue in virtue of the improved thermal shock resistance.

Keywords: functionally gradient materials; FGM; ceramic tool materials; thermal shock resistance; tool life; hot pressing; cutting performance; failure modes; failure mechanisms; tool wear; mechanical fatigue; machining.

DOI: 10.1504/IJMMM.2006.011371

International Journal of Machining and Machinability of Materials, 2006 Vol.1 No.3, pp.277 - 286

Published online: 24 Nov 2006 *

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