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Cutting tool inserts have been fabricated using alumina with different amounts of silver by conventional powder metallurgical route. The machining performance of these composite inserts vis-à-vis that of commercial zirconia toughened alumina inserts have been evaluated by dry turning operations on steel bars under a wide range of cutting parameters. The experiments consisted of measurement and examinations of the static and the dynamic components of the cutting force spectra, flank wear of the tool, surface roughness on the work piece, and chip morphology. Analyses of the fluctuations in the dynamic force spectra using a new approach based on a quasi-fractal model have been used to reveal the potential of different tool materials with respect to their cutting performance. Examinations and pertinent discussion of the operative wear mechanisms during machining by the developed composites vis-à-vis their structure-property relations are some essential supplements of this investigation.

SILVER TOUGHENED ALUMINA CUTTING TOOL INSERTS: PERFORMANCE EVALUATION USING DYNAMIC COMPONENTS OF CUTTING FORCE SPECTRA