Journal of Materials Processing Technology 173 (2006) 151156

The effect of tool wear on tool life of alumina-based ceramic cutting

tools while machining hardened martensitic stainless steel
A. Senthil Kumar
a,
, A. Raja Durai
b
, T. Sornakumar
c
a
Department of Production Engineering, Sethu Institute of Technology, Madurai 626106, India
b
Department of Production Engineering, MIT Campus, Anna University, Chennai 600044, India
c
Department of Mechanical Engineering, Thiagarajar College of Engineering, Madurai 625015, India
Received 18 October 2004; accepted 3 November 2005
Abstract
Tool life is an important parameter in evaluating the performance of the cutting tools. Tool wear affects dimensions and surface quality of the
workpiece and it is also one of the important criteria in determining tool life. When the tool reaches the tool wear criterion, the cutting edge fails
and cannot be used further. Machining studies have been conducted on hardened martensitic stainless steel (HRC 60) to analyse the effect of tool
wear on tool life of alumina ceramic cutting tools. The tool wear such as ank wear, crater wear and notch wear are noted. These wear data are
used to develop mathematical tool wear models using multiple regression analysis (MRA). Tool life of the alumina-based ceramic cutting tools
is evaluated from these tool wear models and the effect of various types of wear on tool life is analysed while machining hardened martensitic
stainless steel.
2006 Published by Elsevier B.V.
Keywords: Tool life; Tool wear; Ceramic cutting tools; Martensitic stainless steel; Multiple regression analysis
1. Introduction
Alumina-based composite ceramic cutting tools are widely
used for machining hard materials such as cast irons having wide
range of hardness, plain carbon steels and alloy steels having a
hardness range of HRC 34 to HRC 66, stainless steels and high
temperature alloys as they have high hot hardness and very good
chemical stability [1]. Aluminium oxide-based ceramic cutting
tools are mainlyclassiedas plainoxide alumina ceramic cutting
tool, mixed alumina ceramic cutting tool and whisker reinforced
alumina ceramic cutting tool. When zirconium oxide is added
to the aluminium oxide matrix, the resulting ceramic tools are
called plain oxide ceramic cutting tools. The fracture toughness
of the ceramic composite increases by the addition of zirconia in
alumina matrix [2]. When non-oxide particles like TiC and TiN
are added in the aluminium oxide matrix, they are called mixed
alumina ceramic cutting tools. The addition of TiC and TiN in
the alumina matrix increases hardness and thermal conductivity
[3]. When whiskers like silicon carbide are reinforced in the alu-

Corresponding author.
E-mail address: asenthil123@yahoo.com (A. Senthil Kumar).
miniumoxide matrix, they are called whisker reinforced alumina
ceramic cutting tools. SiC whisker reinforcement in alumina
matrix increases the fracture toughness of the composite. The
main advantage of the whisker reinforcement is the improved
strength and toughness [3].
The alumina-based ceramic cutting tools are subjected to not
only ank wear but also to crater wear and notch wear, espe-
cially where machining hard and tough materials. Xiao [4] has
observed that zirconia toughened alumina ceramic cutting tools
and TiC mixed alumina ceramic tools are more suitable for
machining hardened steel than other ceramic tools because of
their superior ank wear resistance. Brandt and Mikus [5] have
observed that the crater wear in alumina-based ceramic tools
also affects the performance of the ceramic tools and crater wear
in these tools is predominantly dependent on supercial plastic
deformation when machining steel. Richards and Aspinwall [6]
have observed that the tool life of mixed alumina ceramic tool
is severely limited due to excessive notching, when machining
nickel-based alloys. Thangaraj and Weinmann [7] have studied
the wear behaviour of SiC whisker reinforced alumina ceramic
tools when machining Inconel 718 and they observed that the
ank wear plays a larger role at lower speeds and notch wear
is signicant at higher speed. It is evident that, though the ank
0924-0136/$ see front matter 2006 Published by Elsevier B.V.
doi:10.1016/j.jmatprotec.2005.11.012
152 A. Senthil Kumar et al. / Journal of Materials Processing Technology 173 (2006) 151156
wear is the predominant wear in determining the tool life of
alumina-based ceramic cutting tools; the other types of wear
also affect the tool life. The effect of the various types of wear
on the tool life of alumina-based ceramic cutting tools has to
be thoroughly investigated for their effective utilisation. For this
purpose, detailed tool wear studies were carried out using the
alumina-based ceramic cutting tools while martensitic stainless
steel.
2. Tool wear studies
Tool wear studies have been performed on martensitic stain-
less steel (SS 410 grade), which was previously heat treated to
obtain the hardness value of HRC 60. In our present study four
types of alumina-based ceramic cutting tools such as zirconia
toughened alumina (tool A), Ti[C, N] mixed alumina with zir-
conia addition (tool B), Ti[C, N] mixed alumina (tool C) and SiC
whisker reinforced alumina (tool D) have been used. The details
of composition and properties of the cutting tool materials are
presented in Table 1.
Martensitic stainless steel contains a minimum of 11.5%
chromium and it can be hardened by heat treatment as plain
carbon steels. Martensitic stainless steels are used in thermal
power plants, nuclear power plants and in other demanding envi-
ronments for its high temperature properties, and high creep
rupture strength. Martensitic stainless steel grade 410 (SS 410),
which is used for machining studies contains 11.513.5% of
chromium and 0.090.15% of carbon and each 1% of silicon,
manganese and nickel and small amounts of phosphorus and
sulphur. Machining tests have been carried out in a precision
lathe, using these alumina-based ceramic cutting tools at cutting
speeds of 120, 170, 220 and 270 m/min at a constant feed rate of
0.12 mm/rev and at a constant depth of cut of 0.5 mm, without
any cutting uid. Flank wear, crater wear and notch wear were
measured using tool roommicroscope and micro stylus attached
dial gauge. Surface roughness (R
a
) was measured using surface
roughness meter. Flank wear, crater wear and notch wear data
have been used to develop mathematical wear models.
Flank wear occurs on the tool ank and it is generally
attributed to rubbing of the tool with workpiece at the interface,
causing abrasive and/or adhesive wear and high temperatures
affect the properties of tool material and workpiece materials.
Abrasion is the main wear mechanism in ank wear. Abrasion
Fig. 1. Flank wear region of SiC whisker reinforced alumina ceramic cutting
tool (tool D) on machining martensitic stainless steel.
is characterised by development of grooves and ridges in the
direction of tool sliding against a newly machined surface of the
workpiece or chip sliding against the tool rake. The severity of
abrasion can be increased in cases where the workpiece mate-
rials contain hard inclusions, or when there is debris from the
workpiece or the tool, at the interface. Fig. 1 shows the ank
wear region of SiC whisker reinforced alumina ceramic cutting
tool (tool D) when machining martensitic stainless steel, abra-
sive grooves and ridges can be seen on the tool ank.
Crater wear occurs on the tool rake and toolchip interface
geometry is affected. The most signicant factors inuencing
crater wear are temperature at the toolchip interface and the
chemical afnity between tool and workpiece materials. The
main wear mechanism in crater wear of ceramic tools is the
diffusion of particles into the workpiece. Crater wear involves
chemical reaction between the workpiece chip material and the
ceramic tool material, and the process is activated by high tem-
peratures and is observed mainly at the toolchip interface. It
is thus a tribochemical wear as a result of the chemical afnity
between the workpiece materials and the cutting tool materials
[8]. This type of wear is more pronounced at high cutting speeds
or when there is a high temperature at the toolchip interface,
and is accelerated by a high chemical afnity between the work-
piece and the tool. Fig. 2 shows the photograph of SiC whisker
Table 1
Details of composition and properties of the cutting tool materials
Details of tool material Unit Tool A Tool B Tool C Tool D
Composition Al
2
O
3
(96.5%),
ZrO
2
(3.5%)
Al
2
O
3
(70%), Ti[C,
N] & ZrO
2
(30%)
Al
2
O
3
(70%), TiN (22.5%),
TiC (7.5%)
Al
2
O
3
(80%), SiC
w
(20%)
Insert specication CNGN 12 07 08-T CNGN 12 07 08-T CNGN 12 04 08 T01020 CNGN 12 04 08 T01020
Density g/cm
3
4.02 4.25 4.26 3.74
Vickers hardness HV 1730 1930 1800 2000
Transverse rupture strength MPa 700 620 550 900
Youngs Modulus GPa 380 400 400 390
Fracture toughness MPa m
1/2
4.5 4.5 4.0 8.0
Thermal conductivity W/mK 16 20 24 18
Coefcient of thermal expansion K
1
10
6
8 8 8.6 6
A. Senthil Kumar et al. / Journal of Materials Processing Technology 173 (2006) 151156 153
Fig. 2. Photograph of SiCwhisker reinforced alumina ceramic cutting tool (tool
D) showing crater wear region.
reinforced alumina ceramic cutting tool (tool D) showing crater
wear region on the rake face.
Notch wear occurs by the rubbing of the machined surface
with the cutting tool at the boundary where the chip is no longer
in contact with the tool. Since a machined surface may develop a
thin work hardened layer, this contact could contribute to notch
wear (also called groove wear). The thin hardened layer on the
workpiece surface is hard and abrasive, which increases notch
wear. The notch wear in Ti[C, N] mixed alumina ceramic cut-
ting tool (tool C) when machining martensitic stainless steel is
presented in Fig. 3. Abrasion and adhesion are the main mech-
anisms involved in notch wear, in which individual grains or
their small aggregates are seized of the tool surfaces and are
carried away by the underside of the chip or torn away by the
adherent workpiece. The term seizure is also used to describe
the loss of tool particles from the edge or faces. Weaker inter-
face bonding between different ceramic phases can increase
the severity of adhesion. The adhered workpiece particles often
remain attached to the tool edge. Notch wear is mostly observed
in the ceramic cutting tools, which have low toughness values
[8]. The type of chipproducedis alsoanimportant criterioninthe
Fig. 3. Notch wear in Ti[C, N] mixed alumina ceramic cutting tool (tool C) on
machining martensitic stainless steel.
Fig. 4. Optical micrograph of saw tooth type of martensitic stainless steel chip.
formation of notch wear. As the adhered chip parts fromthe tool
it abrades the cutting tool. Saw tooth chips have been observed
during machining martensitic stainless steel and it is shown in
Fig. 4.
3. Tool life analysis
Tool wear is generally a gradual process and wear rate
depends on tool and workpiece materials, tool shape, cutting u-
ids, process parameters and machine-tool characteristics. Tool
wear in turn adversely affects tool life and it is one of the impor-
tant criteria in determining tool life. Apart from gradual tool
wear, tool fracture or excessive chipping and surface rough-
ness also affect tool life. The tool rejection criteria for rough
machining operation are employed and the following values are
considered from ISO Standard 3685 for tool life testing.
(1) Average ank wear >0.4 mm.
(2) Maximum ank wear >0.7 mm.
(3) Maximum crater wear >0.14 mm.
(4) Notch wear >1.0 mm.
(5) Surface roughness >6.0 mm.
(6) Excessive chipping (aking) or catastrophic fracture of the
cutting edge.
During the machining operation, the observed surface rough-
ness values and the maximum ank wear values were below
the respective stipulated tool rejection criterion at all cutting
conditions. Any catastrophic failure of cutting tools was not
observed during the machining process. Hence, the remain-
ing parameters such as average ank wear, crater wear and
notch wear are considered in this investigation, for evaluat-
ing the tool life of alumina-based ceramic cutting tools on
machining SS 410 steel. Using the wear data obtained from
machining studies, the mathematical models for tool wear are
developed using multiple regression analysis (MRA) and the sig-
nicance of these models are checked by analysis of variance
(ANOVA).
154 A. Senthil Kumar et al. / Journal of Materials Processing Technology 173 (2006) 151156
3.1. Tool wear models
The general purpose of multiple regression analysis is to learn
more about the relationship between several independent or pre-
dictor variables and a dependent or criterion variable. Multiple
regression analysis is widely used for various types of statisti-
cal analysis. In machining studies, the wear of the cutting tool
depends on cutting speed and machining time. Lin et al. [9] have
compared multiple regression analysis and neural network anal-
ysis in the machining studies on composite materials, to analyse
various parameters of machining. Dabade et al. [10] have used
multiple regression analysis to analyse the various parameters
affecting surface roughness in the machining studies using round
insert milling cutter. Jain et al. [11] have modelled the abra-
sive ow machining process using multiple regression analysis
and neural network, and the inuence of machining parameters
on material removal rate and surface nish is analysed. Sree-
jith et al. [12] have conducted machining studies on composite
materials and the optimum machining parameters are analysed
using mathematical model based on multiple regression analy-
sis. Karthikeyan et al. [13] have developed mathematical models
using multiple regression analysis in order to optimise EDM
machining characteristics, such as metal removal rate, tool wear
rate and surface nish and the signicance of the models are
checked by analysis of variance. Paulo Davim [14] has studied
the inuence of cutting parameters on drilling metal matrix com-
posites on tool wear and surface nish using multiple regression
analysis.
Ageneralised ank wear model, crater wear model and notch
wear model based on Taylors tool life equation are used to
analyse machining test results [8]. The constants in these models
are found out using multiple regression analysis with the wear
data collected during machining at various cutting speeds and
cutting time. The wear models are:
Flank wear model : V
B
= a
1
v
b
1
t
c
1
(1)
Crater wear model : K
T
= a
2
v
b
2
t
c
2
(2)
Notch wear model : V
N
= a
3
v
b
3
t
c
3
(3)
where V
B
, K
T
and V
N
denote ank wear, crater wear and notch
wear, respectively, v denotes cutting speed in m/min, t denotes
machining time in minutes and a
1
, b
1
, c
1
, a
2
, b
2
, c
2,
a
3
, b
3
and
c
3
are constants. The wear models of alumina-based ceramic
cutting tools and the indicators of analysis of variance such as
Table 2
Flank wear model of the form V
B
= a
1
v
b
1
t
c
1
and the indicators of analysis of
variance R
2
value and R
2
adj value in the machining of SS 410 steel (HRC 60)
Sl. no Tool Constants of ank wear
model
R
2
value R
2
adj value
a
1
b
1
c
1
1 Tool A 0.0046 0.4805 0.6980 0.996428 0.995237
2 Tool B 0.0032 0.5262 0.7138 0.992474 0.989966
3 Tool C 0.0041 0.4963 0.6955 0.99246 0.989947
4 Tool D 0.0067 0.4497 0.6310 0.995941 0.994588
Table 3
Crater wear model of the form K
T
= a
2
v
b
2
t
c
2
and the indicators of analysis of
variance R
2
value and R
2
adj value in the machining of SS 410 steel (HRC 60)
Sl. no Tool Constants of crater wear
model
R
2
value R
2
adj value
a
2
b
2
c
2
1 Tool A 0.0002 0.7128 0.8142 0.999587 0.999449
2 Tool B 0.0022 0.4301 0.5911 0.99850 0.99799
3 Tool C 0.0029 0.4283 0.5190 0.998851 0.998468
4 Tool D 0.0015 0.5804 0.5506 0.996977 0.99597
Table 4
Notch wear model of the form V
N
= a
3
v
b
3
t
c
3
and the indicators of analysis of
variance R
2
value and R
2
adj value in the machining of SS 410 steel (HRC 60)
Sl. no Tool Constants of notch wear
model
R
2
value R
2
adj value
a
3
b
3
c
3
1 Tool A 0.0011 0.8624 0.8034 0.9961 0.9948
2 Tool B 0.0014 0.7939 0.8001 0.99415 0.9922
3 Tool C 0.0011 0.8628 0.7995 0.993809 0.991745
4 Tool D 0.0015 0.7845 0.7662 0.992881 0.990508
R squared value (R
2
value) and adjusted R square value (R
2
adj
value) are tabulated in Tables 24.
4. Results and discussion
The effect of various types of tool wear on tool life at different
cutting speeds is analysed. The maximum allowable machining
time is calculatedfromthe ankwear, crater wear andnotchwear
models using the respective tool rejection criterion and plotted
against the cutting speed for the alumina-based ceramic cutting
tools in Fig. 5ad. From these gures, it can be noted that the
tool life of the alumina-based ceramic cutting tools is affected by
ank wear at low speeds, and it is affected by either crater wear
or notch wear at high speeds. The tool life of zirconia toughened
alumina ceramic cutting tool (tool A) is affected by ank wear
at low speeds and it is affected by notch wear above 220 m/min.
Similarly, the tool life of Ti[C, N] mixed alumina ceramic cutting
tools (tools B and C) is affected by ank wear at low speeds and
the tool life of tools Band Cis affected by notch wear above 260
and 230 m/min, respectively. However, the tool life of the above
three cutting tools is not affected by crater wear. The tool life of
SiC whisker reinforced alumina ceramic cutting tool (tool D) is
affected by ank wear at low speeds and it is affected by crater
wear above 200 m/min. SiCwhisker reinforced alumina ceramic
cutting tool (tool D) is affected by crater wear because of the
afnity of silicon carbide towards iron. However, the tool life
of tool D is not affected by notch wear. The tool failure occurs
when the tool reaches any one of the tool rejection criteria. In
this study, the tool life of the alumina-based ceramic cutting
tools for particular speed is the machining time when any one
of the tool wear criteria is reached. The tool life of alumina-
based ceramic cutting tools on machining SS 410 steel (HRC
60) is found out from the maximum allowable machining times
A. Senthil Kumar et al. / Journal of Materials Processing Technology 173 (2006) 151156 155
Fig. 5. (a) Maximum allowable machining time vs. cutting speed of tool A calculated using ank wear, crater wear and notch wear criterion; (b) maximum allowable
machining time vs. cutting speed of tool B calculated using ank wear, crater wear and notch wear criterion; (c) maximum allowable machining time vs. cutting
speed of tool C calculated using ank wear, crater wear and notch wear criterion; (d) maximum allowable machining time vs. cutting speed of tool D calculated
using ank wear, crater wear and notch wear criterion.
for different tool wear criteria and it is plotted against cutting
speed in Fig. 6. Ti[C, N] mixed alumina ceramic cutting tool
(tool B) has the maximum tool life followed by Ti[C, N] mixed
alumina ceramic cutting tool (tool C) and zirconia toughened
alumina ceramic cutting tool (tool A). SiC whisker reinforced
alumina ceramic cutting tool (tool D) has lower tool life than
the other alumina-based ceramic cutting tools. For comparison,
a separate tool life studies were conducted on AISI 4340 steel
(HRC 45) under the same machining conditions. It was found
that the crater wear or notch wear did not affect the tool life,
on machining AISI 4340 steel, though crater wear and notch
wear were observed at 270 m/min. However, crater wear and
notch wear play a signicant role in determining the tool life of
the alumina-based ceramic cutting tool especially at high speed
on machining SS 410 steel (HRC 60). Ti[C, N] mixed alumina
ceramic cutting tools exhibits slightly higher tool life than the
other alumina-based ceramic cutting tools due to their ability to
retain hardness at elevated temperatures.
156 A. Senthil Kumar et al. / Journal of Materials Processing Technology 173 (2006) 151156
Fig. 6. Tool life vs. cutting speed of the alumina-based ceramic cutting tools.
5. Conclusion
Tool wear studies wear have been conducted on martensitic
stainless steel (60 HRC) using alumina-based ceramic cutting
tools and various types of wear were observed. Tool life models
are developed using the wear data. The effect of various types
of wear on tool life is analysed. Flank wear affects the tool life
at lower speed, however, crater wear or notch wear affects the
tool life at high speed, i.e. above 200 m/min. The tool life of
Ti[C, N] mixed alumina ceramic cutting tools (tools B and C)
and zirconia toughened alumina ceramic cutting tool (tool A)
is affected by the ank wear at lower speed but it is affected
by notch wear at higher speed. The tool life of SiC whisker
reinforced alumina ceramic cutting tools is affected by ank
wear at lower speed, but it is affected by crater wear at higher
speed. Ti[C, N] mixed alumina ceramic cutting tools exhibit
slightly higher tool life than the other alumina-based ceramic
cutting tools on machining martensitic stainless steel.
6. Industrial summary
Machiningof hardmaterials is foundtobe difcult, especially
in its hardened condition. However, with the development of
new harder work materials, the necessity arises for the industry
to machine such hard materials. The tool materials technology
is advancing at a fast rate to enable machining of these mate-
rials at higher removal rate with reliability of performance. In
the machining of hard materials, cutting tools made of ceramics,
cubic boron nitride (CBN) and poly crystalline diamond (PCD)
are used because of their high hardness. However, poly crys-
talline diamond is totally unsuited for machining steel and other
carbon containing materials. CBN tools are quite costlier than
the ceramic cuttingtools but theyhave equal cuttingperformance
especially in the machining of hardened steel. The ceramic cut-
ting tools are the suitable choice for the industry to machine
hard materials at lower cost among the above-mentioned cut-
ting tools. The tool wear of the ceramic cutting tools affects the
tool life. Tool life of the alumina-based ceramic cutting tools
has been evaluated by the tool wear models developed from tool
wear data collected during the machining studies on martensitic
stainless steel grade 410 (60 HRC). The different types of wear
affecting the tool life of alumina-based ceramic cutting tools
on machining hard materials, can be clearly understood by the
industry fromthis paper, which may lead to the proper utilization
of these tools and selection of proper cutting parameters.
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