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Cutting performance of a new spark plasma sintered SiAlON ceramic tool for high-speed milling of Inconel 718

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Abstract

Two kinds of α/β-SiAlON ceramic tools with different ratio of α-SiAlON to β-SiAlON (10α:90β, 40α:60β) were prepared via spark plasma sintering (SPS). The orthogonal and single-factor experiments were conducted to optimize the milling parameters of the tool. Also, the tool life, failure modes, and wear mechanisms of α/β-SiAlON ceramic tools were studied. The optimal milling parameters for the high-speed face-milling of Inconel 718 by SPS-sintered SiAlON ceramic tools were vc = 800 m/min, fz = 0.12 mm/z, and ap = 1.5 mm. Life of the tool containing high α-SiAlON content (40α:60β) was twice that of the tool with lower content of α-SiAlON (10α:90β), and 2.7 times that of commercially available SiAlON ceramic tool. The SPS-sintered SiAlON ceramic tools displayed better wear resistance than that of a commercially available tool even under recommended cutting parameters of the commercial tool (vc = 1000 m/min, fz = 0.08 mm/z, and ap = 1.5 mm). The failure modes of SPS-sintered tools were dominated by the flaking of rake face, chipping of cutting edge, and flank wear. The primary wear mechanisms were adhesive, diffusive, and abrasive wear.

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Funding

This work was supported by the National Natural Science Foundation of China (52075266, 51875291), Excellent Youth Fund of Jiangsu Province (BK20190070), and Jiangsu Provincial Six Talent Peaks Project (GDZB-016).

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Authors and Affiliations

  1. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, 210094, People’s Republic of China

    Fuzhou Guo, Zengbin Yin, Dongbo Hong, Kejuan Yu & Juntang Yuan

  2. Collaborative Innovation Center of High-End Equipment Manufacturing Technology, Ministry of Industry and Information Technology, Nanjing University of Science and Technology), Nanjing, People’s Republic of China

    Fuzhou Guo, Zengbin Yin, Dongbo Hong, Kejuan Yu & Juntang Yuan

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  1. Fuzhou Guo
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Guo, F., Yin, Z., Hong, D. et al. Cutting performance of a new spark plasma sintered SiAlON ceramic tool for high-speed milling of Inconel 718. Int J Adv Manuf Technol 119, 7327–7338 (2022). https://doi.org/10.1007/s00170-022-08702-6

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