Finite element simulation and experimental analysis of B 4 C‐TiB 2 ‐SiC ceramic cutting tools

Abstract Here, cutting properties and wear mechanism of the home‐made B 4 C‐TiB 2 ‐SiC ceramic cutting tools in turning of AISI 4340 steel workpieces were studied through a combination of finite element simulation using Deform‐3D software and turning experiments. Simulation results show that cutting parameters have significant effects on the main cutting force and tool temperature of the B 4 C‐TiB 2 ‐SiC cutting tool. The optimal cutting parameters for the ceramic cutting tool are cutting speed of 300 m/min, depth of cut of .3 mm, and feed rate of .1 mm/r. Experimental results show the cutting length of the B 4 C‐TiB 2 ‐SiC cutting tool is about 101 m, which is 21.0% and 32.9% larger than that of the home‐made B 4 C‐TiB 2 ceramic cutting tool and commercially available tungsten carbide tool, indicating that the B 4 C‐TiB 2 ‐SiC cutting tool has a desired service life. The surface roughness of the workpieces processed by the B 4 C‐TiB 2 ‐SiC cutting tool is 2.43 µm, which is 29.4% lower than that of the workpieces processed by the B 4 C‐TiB 2 cutting tool, indicating that the B 4 C‐TiB 2 ‐SiC cutting tool has a satisfying machining accuracy. Wear forms of the B 4 C‐TiB 2 ‐SiC ceramic cutting tool involve craters, chipping, and flank wear, and the main wear mechanisms are abrasive, adhesive, oxidative, and diffusion wear.