Materials Science Forum Submitted: 2015-04-18

ISSN: 1662-9752, Vols. 830-831, pp 67-70 Accepted: 2015-05-03

doi:10.4028/www.scientific.net/MSF.830-831.67 Online: 2015-09-03
© 2015 Trans Tech Publications, Switzerland

AlN-TiB2 based self-lubricating ceramic insert fabricated by spark

plasma sintering for dry turning applications
Nambiraj K M1,a*,Rajeswari R1,b, Madhavan S2,c
1
Department of Mechanical Engineering, SSN College of Engineering, Chennai,603110, India
2
Manufacturing Engineering section, Department of Mechanical Engineering, Indian Institute of
Technology Madras, Chennai, 600036, India
a
nambiraj14@gmail.com, brajeswarir@ssn.edu.in, cmadhavan.tes@gmail.com

Keywords: Ceramic insert, AlN-TiB2, Spark plasma sintering, Hardened steel, Dry turning

Abstract
This paper reports the development of a cutting tool insert prepared by consolidation,
followed by Spark Plasma Sintering (SPS) of TiB2 (Titanium diboride) particles processed through
an in-situ reaction and AlN (Aluminium nitride) manufactured by the direct nitridation process. In-
situ TiB2 particles, formed during reaction of KBF4 (Potassium tetra Fluoroborate) and
K2TiF6 (Potassium Fuorotitanate) with Al alloy, are obtained by dissolving the Al-TiB2 composite
in an acidic medium. The extracted TiB2 (30%) particles are blended with AlN and Al2O3 in the
weight ratio of 67%-3% and sintered (SPS) at 1440ºC with a compaction load of 50 MPa and a total
sintering time of 8 minutes. The sintering is carried out in vacuum. The sintered ceramic displays
high hardness of nearly 15.5 GPa and extraordinary toughness of 7MPa.m1/2. The inserts are
manufactured according to SNGN (Square Double-sided ceramic) configuration. To study its
performance, machining is carried out on hardened steel (EN 24). The developed AlN based inserts
show increased wear resistance and provide good surface finish when compared with commercially
available ceramic inserts (70%Al2O3+30%TiC). Cutting forces are recorded with a Kistler®
dynamometer to correlate them with the tool wear. Methods of preparation and comparison of wear
resistance and surface finish of the machined material with those pertaining to commercial ceramic
inserts are also presented. SEM images are displayed, which support the results.

Introduction
Ceramic cutting tools can be used for both rough cutting and finishing operation. Despite
progress in non-conventional manufacturing technologies, metal cutting still plays a major role in
the production of machines, products, apparatus and goods for everyday use. It makes possible
achievement of the highest geometric accuracy of products and produces best surface finish. Hard
turning using ceramic insert have advantages of increased productivity, reduced setup times, surface
finish closer to grinding. Several authors [1-6] reported the performance of ceramic tool in hard
turning. Improved ceramic compositions useful for cutting tools are composed of an essentially
homogenous admixture of sintered powders of aluminum based materials with some other
reinforcement [7].Reduction of oxygen rich surface by using ball mill process has increased the
efficiency of sintering [8]. Plasma activated sintering has higher benefit than conventional hot
pressing in consolidation of difficult-to-sinter powders, including short processing time, fewer
processing steps, elimination of the need for sintering aids and near net shape capabilities[9].
Sintered aluminum nitride base composite with reinforcement enhances strength, hardness,
toughness, wear resistance and exhibit increased heat conductivity [10-12]. Xiang et al. reports that
AlN (64%), TiB2 (30%) and additive Y2O3 (6%) fabricated by spark plasma sintering at 15600 C
with 30MPa uniaxial load for 4 minutes has hardness and toughness nearly13.5 GPa and 4.8
MPa.m1/2[13].
In the current work the fabrication of AlN-TiB2 based ceramic insert is consolidated by
spark plasma sintering (SPS) and the machining is done on hardened steel to study about cutting
force, surface finish and tool wear. The machinability performance of the developed insert is

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68 Advanced Materials and Manufacturing Processes for Strategic Sectors

compared with the commercial insert. SEM images are included to support the result. The
developed ceramic composite insert has greater hardness and toughness than existing one.

Experimental Procedure
A rapid direct nitridation process for the manufacture of sinterable aluminum nitride powder
is developed at pilot scale. Atomized aluminum metal and nitrogen gas are heated and reacted
rapidly to synthesize AlN and passed through the reaction zone of a transport flow reactor In this
process aluminium reacts at a temperature of 17500C with nitrogen gas to form ultrafine AlN
particle [14-15]. The chemical reaction of KBF4 and K2TiF6 with Al alloy produces in situ TiB2
particles. The process parameters involved are reaction time of 30 min, reaction temperature about
7500C.
The raw materials are powders of 67% AlN (3-5µm), 30% TiB2 (3-5µm) and 3% Al2O3 (3-4
µm). They are mixed and milled in planetary ball mill with tungsten carbide ball with ball to
powder ratio of 10:1 for 16 hours at a speed of 240 rpm. Stearic acid is added to prevent
agglomeration during milling. The milled powder mixture is plasma sintered at a temperature of
1440ºC with uniform compaction load 50 MPa for a total sintering period of 8 minutes under
vacuum atmosphere to produce AlN-TiB2 composite. The applied DC current is 1.2-1.3 kA and DC
voltage is 5-6 V. The square shaped insert consists of length of 13 mm and thickness of 4.85 mm
(Fig. 1). The mechanical properties of the inserts are measured. The sintered ceramic has high
hardness of nearly 15.5±1.0 GPa and extraordinary toughness of 7MPa.m1/2. The indentation
toughness is measured by micro Vickers indentation measurement.

Fig (1): AlN-TiB2-Al2O3 Insert specifications

The performance of dry turning is measured in terms of cutting force, surface finish and
tool wear. In this investigation, the work piece material is EN 24 steel of diameter 63 mm. The dry
turning is carried out at a feed rate of 0.1 mm/rev, depth of cut of 0.3 mm for 60 seconds. For each
cutting experiment set (cutting speed of 11.8, 29.6, 71.5 and 264 m/min) new cutting inserts have
been used. Cutting forces are recorded with a Kistler® dynamometer to correlate them with the tool
wear.

Results and Discussion

As shown in figure (2) surface roughness of the AlN-TiB2-Al2O3 insert decreases with
increasing speed. The surface roughness comparison between the developed and commercial inserts
indicates to use the developed insert for dry turning at a speed higher than 29.6 m/min. Fig (3)
shows the flank wear Vs cutting speed comparison between commercial and developed inserts
 Materials Science Forum Vols. 830-831 69

.
Fig (2): Cutting Speed Vs Surface Roughness Fig (3): Cutting Speed Vs Flank Wear

It indicates that the developed insert flank wear is very less compared to commercial insert at
any speed. SEM images of the developed and commercial inserts after dry turning (Fig. 4) supports
the wear test.

(a) (b)

Blunt portion indicating high wear

Fig (4): SEM images of (a) AlN-TiB2-Al2O3 (b) Al2O3+TiC

The cutting force of developed insert (AlN-TiB2-Al2O3) decreases compared with

commercial insert when speed is higher than 71.5 m/min. Fig (5) shows the experimental result.

Fig (5): Cutting Speed Vs Cutting force Fig (6): Cutting force Vs Flank wear

The flank wear of AlN-TiB2-Al2O3 developed insert is very less compared to the commercial insert
with respect to cutting force (Fig. 6).

Conclusion
The hardness (15.5 ± 1.0 GPa) and toughness (7MPa.m1/2) of the developed insert is greater
than commercial insert. The dry turning experiment of hardened steel (EN24) using commercial
(Al2O3+TiC) and developed insert (AlN-TiB2-Al2O3) give the following results: (1) The surface
roughness on EN24 achieved by developed insert is very less compared to commercial insert (2)
The flank wear on the developed insert is also less compared to commercial insert with respect to
cutting speed (3) The cutting force of the developed insert is lower than the commercial insert even
at higher cutting speeds (greater than 71.5 m/min). (4) The flank wear of the developed insert is also
very less compared to the commercial insert at any cutting force. From the above results of the
developed insert, it is well recommended for using it in dry turning applications.
70 Advanced Materials and Manufacturing Processes for Strategic Sectors

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