Strategies for the reconditioning of mixed ceramic cutting inserts applied in the turning of hardened steel

• Grant number: 24/10918-0
• Support Opportunities: Scholarships in Brazil - Doctorate (Direct)
• Start date: April 01, 2025
• End date: March 31, 2030
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Carlos Eiji Hirata Ventura
• Grantee: Lara Souza Martins Fernandes
• Host Institution: Centro de Ciências Exatas e de Tecnologia (CCET). Universidade Federal de São Carlos (UFSCAR). São Carlos , SP, Brazil

Abstract

Due to their high levels of hot hardness and chemical stability when in contact with ferrous materials, mixed ceramic (Al2O3 + TiC) cutting inserts are recommended for machining cast iron and hardened steel. Although they allow the application of higher cutting speeds and obtaining better finishes compared to cemented tungsten carbide, their use brings challenges, mainly due to their high cost and brittleness, which can lead to edge chipping and even breakage during operation. However, the application of this tool material can present advantages when considering the possibility of resharpening, which allows economic gains and contributes to the sustainability of the process. Thus, the project aims to determine strategies for the reconditioning of mixed ceramic cutting inserts applied in the turning of hardened steel. To this end, the following aspects must be investigated: (i) types/mechanisms of tool wear/damage under different process conditions; (ii) optimal conditions for grinding mixed ceramic inserts; (iii) effects of reducing the insert's cross-section on its cutting performance; (iv) possibility of customizing the edge geometry for specific process conditions. Based on the results obtained, in addition to generating knowledge about the processing of mixed ceramic inserts, appropriate strategies must be determined to maximize tool life after resharpening.