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applications and are notoriously difficult to machine Pressure less sintered SiAlON can also increase the tool life by up to 10 times in comparison with silicon nitride tools when machining these alloys
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233 Whisker Reinforced Ceramics
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A new material that has just been introduced and referred to as WG-300 by Greenleaf Corp (Saegertown, PA) [23] holds promise of showing a dramatic improvement in performance This unusual ceramic material is said to have almost twice the fracture toughness of traditional hotpressed ceramics and a significant increase in resistance to thermal shock Its improved performance is said to be attributable to a very uniform dispersion of single-crystal whiskers of silicon carbide The so-called whiskers measure about 06 in (002 m) in diameter and about 40 in (1 m) in length Hexagonal in shape and randomly distributed, these fine strands, as can be seen in AccV Spot Magn Det WD 20 m Figure 217 [24], reportedly serve as reinforcing 300 kV 48 1000x SE 102 whisker SiC/A/203CERAMIC TOOL rods, resulting in the distribution of stress within the matrix The high thermal conductivity of Fig 217: An SEM image of SiC whiskers present in the silicon carbide whiskers conducts heat away the WG300 ceramic insert at a from the cutting edge, thereby reducing thermal magnification of 1000 [24] gradients and resulting stress So impressive were the initial cutting test data on the new WG-300 ceramic composite that Greenleaf omitted several existing lines of ceramic and carbide grades
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Diamond, which is a crystalline form of carbon, has the highest hardness and heat conductivity among all substances and has a very good chemical stability With these excellent characteristics, diamond has found application as a cutting tool; a single-crystal diamond is effective in the ultraprecision machining of non-ferrous system materials, because the extremely sharp edge of the blade that is obtained can be retained for getting an excellent surface finish and dimensional accuracy It has a low tool-chip friction and a high wear resistance Diamond tools can be satisfactorily used at almost any speed but are suitable mostly for light, uninterrupted finishing cuts Because of their strong chemical affinity, diamonds are not recommended for machining plain-carbon steels and titanium, nickel and cobalt-based alloys Diamonds are also used as abrasives in grinding and polishing operations and as coatings [2]
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The use of diamond tools has shown a dramatic increase This is due to the increasing precision of modern machining operations whereby a diamond tool retains its cutting edge virtually unchanged throughout most of its useful life, holding the tolerances set and in many cases reducing the quantity of scrap to zero or nearly zero In addition, a properly designed diamond tool is capable of machining 10 100 times the number of parts formerly machined by conventional high-speed steel or carbide tools Diamonds can routinely machine 10,000 50,000 pieces and, in some cases, can machine as many as 100,000 Fig 218: Structural formula of the pieces in set-ups where carbide tools have machined no more diamond crystal [25] than 300 400 pieces between resharpenings Furthermore, the introductions of new workpiece materials, which are hard and abrasive, have accelerated the use of diamond tools [25] The hardness of a diamond can be explained based on its crystal structure The carbon atoms are arranged in facecentred lattices forming interlocking tetrahedrons and also hexagonal rings on each cleavage plane (Figure 218) Diamond has an indentation or scratch hardness five times that of carbides Figure 219 illustrates the hardness of a diamond compared to other materials according to both Moh s and Knoop s hardness scales However, diamond is relatively brittle and will chip or fracture if it is not carefully handled and protected against shock The machine used should Fig 219: A comparison of Moh and Knoop s hardness of have a minimal vibration or chatter diamond with inorganic materials [25]
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241 Crystallographic Planes [26]
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In order to ensure a long life for diamond tools, especially with regard to the final machining and have a super finish and high accuracy, it is important to choose the type of diamond crystal and attach it in such a way as to simultaneously obtain both minimal flank wear and minimal crater wear In a solitary, anisotropic diamond crystal properties such as the elastic modulus, shearing modulus and hardness change along and within each and every crystallographic plane As a result, the friction forces and the feed forces also change
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