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Cutting performance of silicon-based ceramic end milling tools in high-efficiency machining of GH4099 under dry condition

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Abstract

Ceramic materials have become one of the ideal materials for manufacturing cutting tools in the field of high-speed machining due to their excellent heat resistance, wear resistance, and high temperature strength. Aiming at the difficult-to-machine characteristics of nickel-based superalloy, such as high strength and toughness, low thermal conductivity, and strong viscosity, the cutting performance of four self-developed silicon ceramic end mills defining as S1, S2, S3, and S4 in machining of GH4099 was compared and studied in this work. The cutting force, tool life, cutting temperature, and machined surface roughness were deeply evaluated. The results indicate that the tool life of our developed ceramic tools was 14 times higher than commercial carbide tool at the cutting speed of 400 m/min, and furthermore, their maximum metal removal rate of the ceramic tool could reach 8.15 cm3/min. Besides, the average cutting efficiency of the ceramic tool can be 1.5 times higher than carbide tool in our investigation. It was worth noting that not only the cutting force of the ceramic tool was 13.5% lower but also the machined surface roughness was slightly lower than carbide tool. The wear mechanisms of the ceramic end mills were mainly adhesive wear and diffusion wear. In general, the four self-developed silicon ceramic end milling tools exhibited better cutting performance than carbide tool.

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Funding

This research effort was supported by the National Natural Science Foundation of China (51875319) and Shandong Natural Science Foundation of China (ZR2020ZD05).

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Authors and Affiliations

  1. Centre for Advanced Jet Engineering Technologies (CaJET), School of Mechanical Engineering, Shandong University, 17923 Jing Shi Road, Jinan, 250061, People’s Republic of China

    Hewu Sun, Bin Zou & Wei Chen

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Shandong University, Ministry of Education, Jinan, People’s Republic of China

    Hewu Sun, Bin Zou & Wei Chen

  3. National Demonstration Center for Experimental Mechanical Engineering Education (Shandong University), Jinan, People’s Republic of China

    Hewu Sun, Bin Zou & Wei Chen

Authors
  1. Hewu Sun
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  2. Bin Zou
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  3. Wei Chen
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Contributions

Hewu Sun (first author): conceptualization, methodology, validation, formal analysis, investigation, writing original draft. Bin Zou (corresponding author): conceptualization, formal analysis, resources, writing—review and editing. Wei Chen: Formal analysis. The authors’ contributions correspond their order. All authors read and approved the final manuscript.

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Correspondence to Bin Zou.

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The authors declare no competing interests.

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No conflict of interest exits in the submission of this manuscript, and the manuscript is approved by all authors for publication. This study does not involve human participants and/or animal studies. I would like to declare on behalf of my co-authors that the work described was original research that has not been published previously, and not under consideration for publication elsewhere, in whole or in part. All the authors listed have approved the manuscript that is enclosed.

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Sun, H., Zou, B. & Chen, W. Cutting performance of silicon-based ceramic end milling tools in high-efficiency machining of GH4099 under dry condition. Int J Adv Manuf Technol 118, 1719–1732 (2022). https://doi.org/10.1007/s00170-021-08084-1

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