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Study on helical milling of small holes in zirconia ceramics with PCD tools

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Abstract

Fully sintered zirconia ceramic material (ZrO2) is widely used because of its excellent properties of high strength, high hardness, and excessive temperature resistance. However, machining high quality small holes in ZrO2 workpiece is an ongoing challenge. In this study, the helical milling process using PCD tools is investigated to fabricate high quality small holes in ZrO2. A three-factor and three-level response surface method experiment is designed taking the crack area at the hole entrance (Δw), inner hole surface roughness (Ra) and crack area at the hole exit (Δe) as response values. The influences of spindle speed (n), feed per tooth (fz), and axial depth of cut (ap) on each response value and their interacting relationships are investigated. Then, the regression models of each response value are established. The optimal sets of parameters for helical milling have been obtained by optimizing each independent variable. Furthermore, the accuracy of the constructed regression models has been evaluated. The results demonstrate that Δw, Ra and Δe values are reduced by 73.94%, 82.18%, and 59.08% respectively using the optimized helical milling process and parameters compared with the results before optimization. Two strategies are proposed to further reduce Δe, and the final results demonstrate that Δe can be further decreased by up to 49.56%. Analysis of the cutting edge by SEM shows that the main wear mechanism is stripping wear. The EDS analysis of the cutting edge shows that there is no significant change in the cutting edge material.

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All data generated or analyzed during this study are included in this published article.

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Funding

The study is financially supported by the Natural Science Foundation of Shandong Province (ZR2020ME157) and Shandong Provincial Key Laboratory of Precision Manufacturing and Non-traditional Machining.

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University of Technology, Zibo, 255000, China

    Jinpeng He, Xiang Cheng, Guangming Zheng, Yang Li & Mingze Tang

  2. Histrong Ceramics Co., Ltd., Zibo, 255086, China

    Chuanzhi Luo

Authors
  1. Jinpeng He
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  2. Xiang Cheng
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  3. Guangming Zheng
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  4. Chuanzhi Luo
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  5. Yang Li
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  6. Mingze Tang
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Correspondence to Xiang Cheng.

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He, J., Cheng, X., Zheng, G. et al. Study on helical milling of small holes in zirconia ceramics with PCD tools. Int J Adv Manuf Technol 131, 4773–4796 (2024). https://doi.org/10.1007/s00170-024-13295-3

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  • DOI: https://doi.org/10.1007/s00170-024-13295-3

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