Addition of Nano CaF2@SiO2 and SiC Whiskers in Ceramic Tools for Wear Reduction and Improved Machinability

Abstract

The addition of CaF2@SiO2 and SiC whiskers to ceramic tools can improve their flexural strength and fracture toughness, reduce surface damage, and improve their cutting performance. The cutting experiments showed that under the same cutting conditions, the surface roughness of the workpiece processed with the Al2O3/TiC/SiC/CaF2@SiO2 (ATSC10) tool was significantly lower than that of the workpiece processed with the Al2O3/TiC/ SiC (ATS) tool. Additionally, the main cutting force and cutting temperature when cutting with the ATSC10 tool were lower by 30 and 31.7%, respectively. These results were attributed to the precipitation of CaF2 from the nanocoated particles during cutting and the formation of a uniform and continuous lubricating film on the surface of the tool. The wear on the front surface of the ATS tool was mainly adhesive, and that on the back tool surface was mainly abrasive. For ATSC10, the main forms of wear on the tool front surface were adhesive and abrasive, whereas the main form of wear on the tool back surface was abrasive with slight adhesive wear. The addition of nano-coated particles and whiskers improved the mechanical properties of the cutting tool while maintaining good cutting performance.