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Wear behavior of silicon nitride (Si3N4) ceramic tools in turning gray cast iron was evaluated. Wear of the flank and rake faces decreased with increasing cutting speed in a range of 100 to 300m/min. Deposits on the rake and flank faces after cutting 3.3km were analyzed by electron probe microanalysis (EPMA) and X-ray photoelectron spectroscopy (XPS). When the cutting speed was 300m/min, surface deposits consisting of Mn, S, Al, and O were detected by EPMA. In contrast, little Al and O were found on the tool surface at a cutting speed of 100m/min. Similar results were obtained for the flank face by EPMA. The rake face of the tool after cutting at 300m/min was analyzed in detail by XPS. It was determined that the main contents of the surface deposits were Al2O3 and silicon oxide (SiO2 and SiOx); the layer was 1 to 2μm in thickness. It was revealed that the oxide deposits prevented direct contact between silicon nitride cutting tool and the workpiece. This worked to improve tool life when turning of gray cast iron at a high cutting speed.

Surface Analysis of Silicon Nitride Cutting Tool after Turning Gray Cast Iron.