Fabrication of TiC-TiB 2 composite ceramic tool and its cutting performance in turning austenitic stainless steel

Abstract

New TiC-TiB₂ ceramic cutting tool materials TiC-TiB₂-Ni-Mo (TBNM8) and TiC-TiB₂-Ni (TBN5) with high comprehensive mechanical properties were fabricated by hot pressed sintering with the optimised sintering processes. The cutting performance of TBNM8 in continuously turning austenitic stainless steel (1Cr18Ni9Ti) was experimentally investigated. With the optimal cutting parameters, the cutting performance of TBN5 and commercial tool LT55 were compared in wet and dry turning 1Cr18Ni9Ti. The failure mechanisms of the cutting tools were analysed combined with their high-temperature mechanical properties. The results showed that the tool life of TBN5 and TBNM8 was much longer in continuous dry turning 1Cr18Ni9Ti than that in wet turning, the possible reason was analysed as that the tool materials keeping high mechanical properties at elevated temperature, which led to the great improvement in machining efficiency and good characteristics of environmental friendliness because no cutting fluid was used during the cutting process.

Keywords

austenitic stainless steel 1Cr18Ni9Ti cutting performance tool wear wet and dry turning

Introduction

Austenitic stainless steel is widely used in the welding core, anti-magnetic instrument, medical device and aviation because of its high strength, high modulus of elasticity and high corrosion resistance [1,2]. However, great cutting force and high cutting temperature were produced in the machining of stainless steel due to its high strength and hardness at high temperature, high plasticity, high toughness and low thermal conductivity [3]. The cutting process is unstable, work-hardening is serious and tools are prone to adhesive wear during machining austenitic stainless steel [4 -6]. Therefore, austenitic stainless steel is a kind of typical difficult-to-cut material, the relative machinability is only 30%∼50% of 45 steel [7,8]. Some researchers [9 11] investigated the cutting phenomena, such as the cutting heat, cutting forces and chips, at a notably high cutting speed, but manufactures would rather not apply these parameters because of the short cutting tool life. What's more, few researches have been done about the machining of stainless steel by ceramic cutting tool, especially no more discussion on the tool's failure mechanisms analysed with the high-temperature mechanical properties.

Ceramic cutting tool materials have many unique properties such as high hardness and melting points, good chemical stability and wear resistance, and excellent hardness retaining at elevated temperature [12 -15]. This work is attempting to fabricate a new TiC-TiB₂ composite ceramic tool with high mechanical properties by optimising the sintering process, then investigate its cutting performance in continuously turning 1Cr18Ni9Ti, and thoroughly discuss the possible failure mechanisms of new tool with its high-temperature properties.

Experimental procedures

Experimental methods

TiC-TiB₂ composite ceramic tool materials were fabricated by hot-pressing sintering, the main influencing factors of sintering process were optimised in terms of sintering temperature and holding time respectively at a pressure of 32 MPa in vacuum. The raw materials are shown in Table 1. The mechanical properties of three cutting tool materials are listed in Table 2. The test methods for mechanical properties have been described in our previous literature [12].

Table 1

The raw materials.

Components	Average particle size (μm)	Purity (%)	Source
TiC	0.5	99.8	Company of Hefei Mo Ke
TiB₂	1.0	99.8	Nano Technology Company of Shanghai Chao Wei
Ni	0.8	99.9
Mo	0.4	99.9

Table 2

The properties of three kinds of compared tool materials (at ambient temperature).

Tool	Main components	Fracture toughness (MPa·m^1/2)	Flexural strength (MPa)	Vickers hardness (GPa)
LT55 [16]	Al₂O₃-TiC-Mo-Ni	5.04	900	21.50
TBN5	TiC-TiB₂-Ni	6.86	932	20.14
TBNM8	TiC-TiB₂-Ni-Mo	7.18	921	22.40

The specimens were cleaned in acetone solution by ultrasonic wave, the density of the material was measured by Archimedes drainage. In order to reduce the artificial measurement error, six specimens were used each time, and each specimen was measured three times. Generally, the ratio of the average density measured by the material and the theoretical density calculated according to the complete density of the material is used to measure the relative density.

Cutting experiments design

The cutting experiments were carried out on the PUMA200 CNC lathe with coolant. Pouring process was performed and the extreme pressure emulsion was used as a coolant during wet continuous turning, it is poured as close as possible to the cutting zone and the contact zone of the rake face. Ceramic cutting tools TBN5, TBNM8 and LT55 were used in turning 1Cr18Ni9Ti respectively. TBN5 and LT55 were designated for comparison in this research.

All the cutting tools to be used were prepared to an identical geometry as shown in Table 3. The chemical composition and room temperature mechanical properties of the austenitic stainless steel provided by the supplier are shown in Tables 4 and 5 respectively. Physical drawings of three kinds of cutting tools are shown in Figure 1. Six tips of each cutting tool were used for repeated tests under the optimal cutting parameters.

Table 3

Cutting tool geometry.

Normal rake angle γ₀	Normal clearance angle a₀	Major cutting edge inclination angle l_s	Major cutting edge angle K_r	Chamfered width and edge
−5°	5°	–5°	45°	0.1mm × –15°

Table 4

The compositions of the austenitic stainless steel.

Material	C	Si	Mn	Ni	Cr	Ti	Fe	S	P
1Cr18Ni9Ti	0.045	0.6	0.94	8.1	17.24	0.29	remain	0.001	0.033

Table 5

The mechanical properties of the austenitic stainless steel.

Yield strength σ_0.2 (MPa)	Tensile strength σ_b (MPa)	Elongation δ₅ (%)	Reduction of area ψ (%)	Hardness HBS
217	534	44	53	189

During the course of the cutting tests, the tool flank wear was checked frequently with a tool microscope, the tool wear morphology was surveyed by a laser scanning microscope (LSM, VKX200K, Keyence, Japan), scanning electronic microscope (SEM Zeiss Supra-55, Germany) attached with energy dispersive spectrometer (EDS).

Results and discussion

Fabrication of TiC-TiB₂ ceramic cutting tool materials

Optimisation of sintering temperature

Design of composition and sintering temperature

The melting points of Ni and Mo are 1455°C and 3200°C respectively. The eutectic temperature of Ni–Mo binary alloy is 1310°C. In order to form liquid phase sintering and obtain high density, the sintering temperature of TiC-TiB₂ ceramic cutting tool materials must be higher than the eutectic temperature of Ni-Mo binary alloy. However, excessively high sintering temperature will lead to abnormal grain growth and reduce the mechanical properties of the materials. At the same time, it has high energy consumption and high cost. Therefore, this study optimised the sintering temperature range from 1400°C to 1650°C. The composition ratio and sintering process of the optimised sintering temperature test are shown in Table 6. The fixed holding time was 30 min and the sintering pressure was 32 MPa.

(2) Effect of sintering temperature on mechanical properties

Table 6

The composition ratio and sintering process at different sintering temperature.

Test number	TiC (wt-%)	TiB₂ (wt-%)	Ni (wt-%)	Mo (wt-%)	Sintering temperature (°C)
N1	60.11	34.89	5	0	1400
N2	60.11	34.89	5	0	1450
N3	60.11	34.89	5	0	1500
N4	60.11	34.89	5	0	1550
N5	60.11	34.89	5	0	1600
N6	60.11	34.89	5	0	1650
N7	58.22	33.78	4.45	3.55	1400
N8	58.22	33.78	4.45	3.55	1450
N9	58.22	33.78	4.45	3.55	1500
N10	58.22	33.78	4.45	3.55	1550
N11	58.22	33.78	4.45	3.55	1600
N12	58.22	33.78	4.45	3.55	1650

Figure 2 shows the mechanical properties of TBNM8 and TBN5 at different temperatures. It can be seen that flexural strength and Vickers hardness of TBNM8 and TBN5 first increased and then decreased with the increase in sintering temperature, but the fracture toughness presented an uncertain law. Sintering temperatures were range from 1450°C to 1600°C, the fracture toughness of materials were higher than 7 MPa·m^1/2. But at the sintering temperatures of 1650°C, the fracture toughness of materials decreased rapidly, the specific reasons were analysed in the next section combined with microstructure. The optimum comprehensive mechanic properties of the TBNM8 and TBN5 were obtained at the sintering temperature of 1450°C.

(3) Effect of sintering temperature on microstructure

Figure 3 shows the SEM of fracture morphology of TBN5 at different sintering temperatures. It can be seen that TBN5 had a lower porosity, the density of the materials were higher and the grain distribution was more uniform at the sintering temperature of 1450°C (as shown as in Figure 3(b)). The microstructure of TBNM8 would not be repeated here because it was similar to that of TBN5. So the relatively superior comprehensive mechanical properties of TBN5 and TBNM8 were obtained at 1450°C. However, as the sintering temperature continued to rise, the grain size of the metal ceramic materials grew, which reduced the density of the composites. At the same time, as the sintering temperature was much higher than the melting point of the metal phase Ni and the eutectic temperature of Ni–Mo, the interfacial bonding strength of the added phase and the matrix phase became weaker, thus the mechanical properties of the material were reduced.

Optimisation of holding time

Composition and sintering process

In this study, the holding time of 15, 30 and 45 min was selected for optimisation. The composition ratio and sintering process of the optimised holding time test are shown in Table 7. The fixed sintering temperature was 1450°C and the sintering pressure was 32 MPa.

(2) Effect of holding time on mechanical properties and microstructure

Table 7

The composition ratio and sintering process at different holding time.

Test number	TiC (wt-%)	TiB₂ (wt-%)	Ni (wt-%)	Mo (wt-%)	Holding time (min)
N13	60.11	34.89	5	0	15
N14	60.11	34.89	5	0	30
N15	60.11	34.89	5	0	45
N16	58.22	33.78	4.45	3.55	15
N17	58.22	33.78	4.45	3.55	30
N18	58.22	33.78	4.45	3.55	45

Figure 4 shows the mechanical properties of TBN5 and TBNM8 at different holding time. The TiC-TiB₂ metal ceramic cutting tool material obtained the optimal comprehensive mechanical properties when the holding time was 30 min.

Figure 5 shows the SEM of polished surfaces of TBN5 at different holding time. Table 8 shows the relative density of TBN5 at different holding time. As can be seen from Figure 5(a,b), with the holding time increasing from 15 to 30 min, the grain size in the material grew, the porosity decreased, the density increased (as shown as in Table 8) and the microstructure of the material was uniform. However, as the holding time continued to increase (as shown in Figure 5(c)), the grain size in the material grew abnormally, the porosity increased and the microstructure of the material was not uniform. The TBN5 obtained relatively superior comprehensive mechanical properties when the holding was 30 min. The microstructure of TBNM8 would not be repeated here because it was similar to that of TBN5.

Table 8

The density of TBN5 at different holding time.

Test number	Holding time (min)	Relative density
N13	15	97.2%
N14	30	99.8%
N15	45	98.6%

To sum up, this study fabricated TiC-TiB₂ ceramic cutting tool materials with high comprehensive mechanical properties at room temperature by vacuum hot-pressing sintering process. The optimal sintering processes were the sintering temperature of 1450°C and holding time of 30 min. Under the optimal sintering processes, the flexural strength, Vickers hardness, fracture toughness were 932.3±70 MPa, 20.14±1.1 GPa and 6.86±0.60 MPa·m^1/2 for TBN5 and 921.2±140 MPa, 22.4±1.0 GPa and 7.18±0.5 MPa·m^1/2 for TBNM8 respectively.

Analysis of cutting experiments

The experiment results of orthogonal tests are shown in Table 9. On the premise of ensuring the surface quality of semi-finished products, the optimum cutting parameters for continuous wet turning and dry turning austenitic stainless steel for composite ceramic cutting tool were determined with material removal as the optimisation objective. Relationships of tool life with three cutting parameters in wet turning 1Cr18Ni9Ti based on Table 9 according to the Taguchi Method [17] are shown in Figure 6. But it was difficult to distinguish the degree of influences of the different cutting parameters on the tool life only from Figure 6, because the variation range of the cutting depth was larger than the other two parameters. In order to overcome this problem, a mathematical formula was deduced. The experimental for tool life as function of cutting parameters is [18]: (1) where T is tool life, v is cutting speed, f is feed rate, a_p is cutting depth, C, a, b, c are constant. Based on the data in Table 9, regression of mathematical expressions and the effect of cutting speed, feed rate, cutting depth on the tool life can be achieved by programming and using Matlab software: (2) It was seen from Equation (2), feed rate had the greatest influence on the tool life due to its exponents more than the others and an increase in the feed rate availed the tool life to some extent in turning 1Cr18Ni9Ti (as shown as in Figure 7). The improvement of feed rate to a certain extent avoided the cutting edge working in the cold hard layer formed by the last feed. An increase in the cutting speed and cutting depth reduced the tool life.

Table 9

The orthogonal experiment design and the results.

Experiment number	Cutting speed A(m min⁻¹)	Cutting depth B(mm)	Feed rate C(mm r⁻¹)	Amount of material removal (mm³)	The cumulative cutting time (min)	Surface roughness Ra (μm)
1	80 (A₁)	0.10 (B₁)	0.10 (C₁)	4917.7	6	1.89
2	80 (A₁)	0.20 (B₂)	0.125 (C₂)	24355.0	12	2.93
3	80 (A₁)	0.30 (B₃)	0.15 (C₃)	28426.4	7	3.2
4	100 (A₂)	0.10 (B₁)	0.125(C₂)	19532.3	13	2.29
5	100 (A₂)	0.20 (B₂)	0.15 (C₃)	13343.6	4	3.19
6	100 (A₂)	0.30 (B₃)	0.10 (C₁)	6496.9	2	2.22
7	120 (A₃)	0.10 (B₁)	0.15(C₃)	24348.4	13.5	2.14
8	120 (A₃)	0.20 (B₂)	0.10 (C₁)	11994.3	4.5	2.47
9	120 (A₃)	0.30 (B₃)	0.125 (C₂)	5622.3	1	2.72
Optimum	80(A₁)	0.20(B₂)	0.15(C₃)	71325.9	29.5	2.81

The increase in cutting speed and cutting depth depressed the tool life in turning 1Cr18Ni9Ti. Since the exponents of cutting speed is greater than the exponents of cutting depth, the increase in cutting speed has a greater impact on the reduction of tool life than the increase in the cutting depth.

Relationship of amount of material removal with three cutting parameters in wet turning 1Cr18Ni9Ti based on Table 9 according to the Taguchi Method [17] is shown in Figure 8. It was seen from that the value of amount of material removal increased with the feed and the variation range of the feed was larger than that of the other two parameters. The cutting amount decreased first and then increased slightly with the increase in cutting speed and the cutting amount increased first and then decreased with the increase in cutting depth.

Comprehensive analysis, the best cutting parameters of the TBNM8 tool were obtained as follows: the cutting speed was 80 m min⁻¹, the cutting depth was 0.20 mm, and the feed speed was 0.15 mm r⁻¹.

Tool failure mechanisms

The cutting tool wear curves in wet and dry turning 1Cr18Ni9Ti are shown in Figure 9. Figure 9 depicts that the new advanced ceramic cutting tools TBN5 and TBNM8 had much longer tool lives when continuously dry turning 1Cr18Ni9Ti than wet turning, which led to the great improvement in machining efficiency, cutting fluid cost reduction and good characteristics of environmental friendliness because no cutting fluid was used during the cutting process. From the analysis of Figure 9, the flank wear of the three kinds of tools in wet and dry turning 1Cr18Ni9Ti were increased with an increase in cutting time, the wear speed of LT55 was the fastest among three cutting tools, the wear speed of TBN5 and TBNM8 was fast first then steadily and accelerated at last.

The wear damage morphologies of rake face of TBN5, TBNM8 and LT55 under the cutting parameters (v = 80 m min⁻¹, f = 0.15 mm r⁻¹, a_p = 0.20 mm) in dry turning 1Cr18Ni9Ti are shown in Figure 10. Figure 10 shows the LSM topographies of the rake face of three worn inserts when dry turning 1Cr18Ni9Ti that correspond to Figure 9(b). Both two- and three-dimensional micrographs were provided. The crater of TBNM8 was located on the rake face in Figure 10(b), and the crater wear was more serious than the other two cutting tool. The 3D morphology of TBN5 (Figure 10(a)) and LT55 (Figure 10(c)) reveals that the damage rake surface did not display a heavy crater but a cutting edge chipping. The tool life may be reduced immediately before total destruction because of this edge chipping [8].

SEM micrographs and EDS spectrums of the damage on the flank face of TBN5, TBNM8 and LT55 in dry turning 1Cr18Ni9Ti are shown in Figures 11–13, respectively. Figures 11(a), 12(a), and 13(a) show the flank wear morphologies of the three compared cutting tools. The obvious phenomenon of the main cutting edge chipping was observed under the optimal cutting parameters. In which the tool chipping of TBNM8 was slight, followed by TBN5, the worst was the LT55. Some heavy grooves were observed on the flank face (see Figure 11(a)). A chipping region was magnified in Figure 11(b), it was a fracture texture without any adhesion inside the notch (see Figure 11(d)). On the basis of Figure 11(c,f), the elements (Fe, Cr, Ni, Mn, Si, Ti, C) contented in this area was found to be the same as that of the workpiece material. It indicated that adhesive wear was happed in TBNM8. Figure 11(e) shows that workpiece material elements such as Ni and Fe were found in addition to the elementary composition of cutting tool material and the contention of 11.18 wt-% O elements were also found in this area, which indicated that TBNM8 had slight diffusion wear and oxidation wear at the same time. Some heavier damages of the inserts were found in Figure 12(a) and some elements of the workpiece materials diffused into the flank face to cause some slight adhesive wear in Figure 12(c,e). 17.53 wt-% O elements were found in Figure 12(b,d), therefore, TBNM5 had more serious oxidation wear than TBNM8. Workpiece material elements such as Fe, Cr and Ni were found in Figure 12(d) which indicated that TBN5 had slight diffusion wear and oxidation wear at the same time. The heaviest damages of the inserts are found in Figure 13(a) and some elements of the workpiece materials diffused into the flank face to cause some slight adhesive wear in Figure 13(b,d). Failure mechanisms of the cutting tools TBN5, TBNM8 and LT55 in wet turning were consistent with those in dry turning, this would not to be further stated.

So the failure mechanisms of TBN5 and TBNM8 were adhesive wear, slight diffusion wear and oxidation wear, and the failure mechanism of LT55 was adhesive wear during continuously dry turning 1Cr18Ni9Ti. The oxide film can reduce the friction coefficient during turning, therefore, the wear rate of TBN5 and TBNM8 was lower than that of LT55. No oxide film had been formed at the beginning of turning, so TBN5 and TBNM8 wear faster at the beginning. However, with the formation of oxide film, the wear rate tended to be stable gradually, and finally the tool failed rapidly due to the damage of rake face and cutting edge chipping. This was consistent with the wear curve of the three kinds of tools shown in Figure 9.

To sum up, TBN5 and TBNM8 were more suitable for continuously dry turning than wet turning 1Cr18Ni9Ti, the possible reasons were analysed as follows:

At 800°C, the flexural strengths, fracture toughness were 760.1±80 MPa and 8.7±0.50 MPa·m^1/2 for TBN5, and 840.2±110 MPa and 9.8±0.5 MPa·m^1/2 for TBNM8 respectively, which means that TBN5 and TBNM8 maintained higher comprehensive mechanical properties at high temperature [14]. The excellent high-temperature characteristics of the present composite ceramic make it feasible to be used as a cutting tool material for cutting difficult-to-cut materials.

The cutting temperature of TBN5 and TBNM8 in dry turning austenitic stainless steel is roughly between 440°C and 455°C. Although serious oxidation wear hardly happened for TBN5 and TBNM8 under this temperature, the hardness of austenitic stainless steel decreased sharply when the temperature was higher than 400°C. Studies have shown that using temperature of austenitic stainless steel is usually under 400°C and the hardness decreasing with the temperature increases, the temperature of 400°C hardness falls sharply. Therefore, TBN5 and TBNM8 are more suitable for continuously dry turning.

Conclusions

TiC-TiB₂ composite ceramic cutting tool materials were prepared and their mechanical properties and microstructure obtained by different sintering temperature and holding time were studied. The high comprehensive mechanical properties of TiC-TiB₂ composite ceramic cutting tool materials resulted from the sintering processes with the sintering temperature of 1450°C and the holding time of 30 min.

TBN5 and TBNM8 were more suitable for dry turning 1Cr18Ni9Ti. The cutting tool life of LT55 was only 10 min, and the cutting tool life of TBNM8 and TBN5 were 34 min and 19.5 min respectively in dry turning austenitic stainless steel. The result of this research has not only practical value by prolong cutting tool life but also environmental friendly by eliminating the consumption of cutting fluid.

The failure forms of TBN5 and TBNM8 were the damage of rake face and cutting edge chipping, which led to the rapid failure of the tool, the failure mechanisms of TBN5 and TBNM8 were adhesive wear, slight diffusion wear and oxidation wear, and the main failure form of LT55 was the cutting edge chipping and the failure mechanism of LT55 was adhesive wear during continuously dry turning 1Cr18Ni9Ti. Failure mechanisms of the three kinds of cutting tools in wet turning were in consistent with those in dry turning.

Footnotes

Disclosure statement

No potential conflict of interest was reported by the authors.

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Fabrication of TiC-TiB 2 composite ceramic tool and its cutting performance in turning austenitic stainless steel

Abstract

Keywords

Introduction

Experimental procedures

Experimental methods

Cutting experiments design

Results and discussion

Fabrication of TiC-TiB2 ceramic cutting tool materials

Optimisation of sintering temperature

Optimisation of holding time

Analysis of cutting experiments

Tool failure mechanisms

Conclusions

Footnotes

References

Fabrication of TiC-TiB₂ ceramic cutting tool materials