IMPROVING THE TOOL LIFE OF CERAMIC CUTTING INSERT WHEN MACHINING DIFFICULT-TO-CUT ALLOY STEEL

Abstract

Inconel is a nickel-based super alloy with a promise in industrial applications
requiring high specific strength and corrosion resistance, namely, automobile,
aerospace, jet engine, waste processing, marine equipment and oil and gas
extraction. However, unlike traditional materials such as steel and aluminum, its
machinability rating is poor, that is, it is very difficult to machine. Accordingly,
the tool life in machining of Inconel is substantially less than traditional
materials. This article proposes various techniques employed in improving the
tool life of ceramic cutting insert as compared to commercial cutting tool.
Experimental tests were carried out to check the efficiency of one of the
proposed techniques using ISO 3685 standard. The results revealed that notch
and flank wears were dominant morphology during cutting process.
Furthermore, the tool life of the designed inserts could be remarkably improved
76.47% over the commercial cutting tool.