A systematic material design approach to develop self-lubricating ceramic-composite tool inserts for dry cutting conditions

Syed Sohail Akhtar*

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

1 Scopus citations

Abstract

A systematic approach is the focus of the current work in order to design and develop ceramic composites for cutting tool inserts with a balanced combination of structural and thermal properties together with enhanced antifriction characteristics. In the material design stage, various combinations of ceramic materials and inclusions with optimum self-lubricating attributes are selected based on predictions of mechanical and thermal properties using in-house built codes. A mean-field homogenization scheme is used to predict the constitutive behavior while J-integral based fracture toughness model is used to predict the effective fracture toughness of the ceramic composites. An effective medium approximation is used to predict the potential optimum thermal properties. The current strategy incorporates thermal and structural properties of composites as a constraint on the design process together with self-lubrication property. Among various metallic and carbon-based fillers, silicon carbide (SiC) together with titanium oxide (TiO2) and graphite are found the most suitable candidate fillers in alumina (Al2O3) matrix to produce cutting inserts with best combinations of thermal, structural and tribological properties. As a validation, various combinations of Al2O3-SiC-TiO2 and Al2O3-SiC-TiO2 composites are developed in line with the designed range of filler size and volume fraction using Spark Plasma Sintering (SPS) process to complement the material design.

Original languageEnglish
Title of host publicationAdvanced Materials
Subtitle of host publicationDesign, Processing, Characterization, and Applications
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791859490
DOIs
StatePublished - 2019

Publication series

NameASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)
Volume12

Bibliographical note

Publisher Copyright:
Copyright © 2019 ASME.

Keywords

  • Composites
  • Design
  • Self-lubricating
  • Spark plasma sintering

ASJC Scopus subject areas

  • Mechanical Engineering

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