The Performance Evalution of Ceramic And Carbide Cutting Tools In Machining of Austemepered Ductile Irons

Abstract

The aim of this research is to compare TiN (PVD) coated Al2O3+Ti[C,N] mixed alumina-based (KY4400) ceramic and CVD coated carbide TiC+AI2O3+TiN (ISO P25) cutting tools in turning austempered ductile irons. Ductile cast iron samples were austenitized at 927°C and subsequently austempered for 1 hour at 400°C. The hardness of the workpiece material was measured and found to be 43.5 HRC. In the present work a series of tests were conducted in order to evaluate the tool performances by adopting tool life. In all experiments cutting forces, flank wear and surface roughness values were measured throughout the tool life. No cutting fluid was used during the turning operations. Study of the tool life and failure modes shows that tool life was determined by the flank wear and surface roughness generated on the workpiece. The main conclusion is that tool life of ceramic insert was longer than the coated carbide insert although much higher cutting speeds were used. 

Keywords

• ceramics; wear; tool life; cutting force; ductile iron

Östemperlenmiş Küresel Grafitli Dökme Demirlerin İşlenmesinde, Seramik ve Karbür Kesicilerin Performanslarının Karşılaştırılması

Abstract

Östemperlenmiş küresel grafitli dökme demirler, üstün mekanik özelliklerinden dolayı, son yıllarda, birçok endüstriyel alanda mühendislik malzemesi olarak kullanılmaktadır. Bu çalışmada, PVD kaplamalı aluminyum oksit esaslı seramik Al2O3+Ti[C,N] (KY4400) ile CVD kaplamalı karbür kesici takımların TiC+AI2O3+TiN (ISO P25), östemperlenmiş küresel grafitli dökme demirlerin işlenmesindeki performansları karşılaştırılmıştır. Deneylerde kullanılan ÖKGDD numuneler, ilk olarak 927°C’de 90 dakika östenitlemeden sonra, tuz eriyiğinde 400°C’de 1 saat östemperlenmiştir. Sertlik 43,5 HRC olarak ölçülmüştür. Deneylerde, takım ömrü süresince kesme kuvvetleri, serbest yüzey aşınması ve yüzey pürüzlülüğü değerleri ölçülerek karbür ve seramik kesici takımların performansları karşılaştırılmıştır. Seramik kesici takımlar ile talaş kaldırma işleminde daha yüksek kesme hızı kullanılmış olmasına rağmen, karbür kesici takımlardan daha yüksek yüzey kalitesi ve daha uzun takım ömrü elde edilmiştir. 

Keywords

• Seramik, aşınma, takım ömrü, kesme kuvveti, dökme demir

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