Research on High Performance Milling of Engineering Ceramics from the Perspective of Cutting Variables Setting

The setting of cutting variables for precision milling of ceramics is important to both the machined surface quality and material removal rate (MRR). This work specifically aims at the performance of corner radius PCD (polycrystalline diamond) end mill in precision milling of zirconia ceramics with relatively big cutting parameters. The characteristics of the cutting zone in precision milling ceramics with corner radius end mill are analyzed. The relationships between the maximum uncut chip thickness (h_max) and the milling parameters including feed per tooth (f_z), axial depth of cut (a_p) and tool corner radius (r_ε) are discussed. Precision milling experiments with exploratory milling parameters that cause uncut chip thickness larger than the critical value were carried out. The material removal mechanism was also analyzed. According to the results, it is advisable to increase f_z appropriately during precision milling ZrO₂ ceramics with corner radius end mill. There is still a chance to obtain ductile processed surface, as long as the brittle failure area is controlled within a certain range. The appropriate increasing of a_p, not only can prevent the brittle damage from affecting the machined surface, but also could increase the MRR. The milling force increases with increasing MRR, but the surface roughness can still be stabilized within a certain range.