friction and wear analysis of ceramic cutting tool made ... · muhammad hafiz hassan 3 1 centre of...

Jurnal Tribologi 24 (2020) 27-38

Received 27 September 2019; received in revised form 21 December 2019; accepted 17 January 2020.

To cite this article: Azhar et al. (2020). Friction and wear analysis of ceramic cutting tool made from Alumina-

Zirconia-Chromia. Jurnal Tribologi 24, pp.27-38.

© 2020 Malaysian Tribology Society (MYTRIBOS). All rights reserved.

Friction and wear analysis of ceramic cutting tool made from Alumina-Zirconia-Chromia Anis Afuza Azhar 1, Mohd Hadzley Abu Bakar 1*, Norfauzi Tamin 2, Umar Al-Amani Azlan 2, Muhammad Hafiz Hassan 3 1 Centre of Smart System and Innovative Design (CoSSID), Fakulti Kejuruteraan Pembuatan, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, MALAYSIA. 2 Fakulti Teknologi Kejuruteraan Mekanikal dan Pembuatan, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, MALAYSIA. 3 Gandtrack Asia Sdn. Bhd., No. 17, Jalan Tasik Utama 65, Kawasan Perindustrian Taman Tasik Utama, 75450 Ayer keroh, Melaka. MALAYSIA. *Corresponding author: [email protected]

KEYWORDS ABSTRACT

Alumina Zirconia Chromia Coefficient of Friction Pin on Disc

This research focused on the friction and wear analysis of ceramic cutting tool made from Al2O3, ZrO2 and Cr2O3. 80 wt% of Al2O3 and 20 wt% of ZrO2 compacts were prepared by ball milling process with Cr2O3 addition at the variation of 0.2, 0.4, 0.6 and 0.8 wt%. Each sample was pressed by Cold Isostatic Press at 350 MPa before sintered at the constant temperature of 1400oC and 9 hours soaking time. Relative density, hardness, flexural strength and Pin-on-disc tribotest were performed for each sample. The samples with desired mechanical properties were further machined with AISI 1045 at the cutting speed of 200 m/min, 0.175 mm/rev feed rate and 0.5 mm depth of cut. The results show the sample with composition ratio of Al2O3-ZrO2-Cr2O3 at 80-20-0.6 wt% demonstrated lowest Coefficient of Friction (COF) of 0.23 with hardness and relative density recorded at 71.3 Hrc and 95.81% respectively. Microstructure of Al2O3-ZrO2-Cr2O3 presenting significant grains compaction as compared to Al2O3-ZrO2 and single Al2O3 that showed significant appearance of porosity. In terms of tool wear, Al2O3-ZrO2-Cr2O3 performed 51% and 800% better tool life than Al2O3-ZrO2 and Al2O3 cutting tools.


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1.0 INTRODUCTION Machining is a process to produce a component by shearing the material into the required

shape. To machine a high strength component, the machining process is often associated with high generation of heat (Talib et Al., 2017; Mahalil et al., 2019). The heat that is generated during machining is frequently related to the initial tool wear of the cutting tool, which is detrimental to the machined surface. Therefore, a cutting fluid or coolant is often used during machining to reduce heat and provide lubrication. However, excessive usage of coolant may not only consume a large cost but also may cause a dermatitis problem to the machine operators (Emami et al., 2014). To avoid the usage of excessive coolant during machining, a cutting tool which can perform in dry condition and high hot hardness is preferred (Norfauzi et al., 2019; Broniszewski et al., 2015; Rakshit & Das, 2019).

One of the cutting tools that are well known for high hot hardness and capable of performing in dry conditions is zirconia toughened alumina (ZTA). ZTA comprises alumina and zirconia powders that are blended by the powder metallurgy process. This material is reported to have enormous hardness, refractory, heat stability, and chemical inertness (Hadzley et al., 2019; Kern et al., 2015). Therefore, a ZTA-based cutting tool is commonly used to machine mild steel, hardened steel, and high strength steel.

To fabricate a ZTA-based cutting tool, processing parameters, such as compaction pressure, sintering temperature and soaking time, influence the reliability and long-term durability of Al2O3 and ZrO2 mixture. In addition, a selection of suitable powders and binders should be correctly mixed to suit the specific requirements of the intended application (Zhwan et al, 2018; Amran et al., 2015). Current research studies to improve the strength of ZTA were mainly focused on the addition of tertiary materials to alter their microstructures. For example, Oungkulsolmongkol et al., (2010) tried to improve the mechanical properties of Al2O3-ZrO2 by developing the Al2O3-ZrO2-SrO composite, Grigoriev et al., (2016) fabricated Al2O3-ZrO2-TiC composite ceramic cutting tool by hot press method, Azhar et al., (2017) produced Al2O3-ZrO2 cutting insert that was coated with titanium nitrate (TiN), and Singh et al., (2018) developed Al2O3-ZrO2-MgO or Mg-ZTA for cutting tool application.

As the research and development of Al2O3-ZrO2 are still in progress with various formulations, the study in regard to the effect of chromia (Cr2O3) on the Al2O3-ZrO2 is still limited in terms of mechanical properties, tribology and wear performance. For the last 10 years, only few research studies concentrated on the development of the Al2O3-ZrO2 cutting tool that was reinforced with the Cr2O3 addition. For example, Azhar et al., (2012) initiated a study to improve the mechanical properties of Al2O3-ZrO2 by adding different compositions of Cr2O3. The study presented the microstructural analyzes in relation to hardness and fracture toughness of Al2O3-ZrO2-Cr2O3. The study suggested that larger grains in the form of platelike shape were responsible for the improvement of hardness, fracture toughness, and wear performance of Al2O3-ZrO2-Cr2O3.

In another study, Singh et al. (2016) fabricated Al2O3-ZrO2 that was doped with Cr2O3 (Cr-ZTA) cutting tools for high speed machining. The effective content of Cr2O3 was studied to obtain the optimum cutting parameters for minimum tool wear, surface roughness, and cutting force. The study suggested that the addition of Cr2O3 up to 0.6 wt% was desired for maximum hardness and fracture toughness.

Manshor et al., (2016) altered the composition of Al2O3-ZrO2 cutting tool with the addition of Cr2O3 and titanium oxide (TiO2). The addition of Cr2O3 to the Al2O3-ZrO2-Cr2O3-TiO2 composites promoted platelike grains development for the dominant alumina structure. The


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Cr2O3addition of up to 0.6 wt% promoted improvement in grain size, together with the density and fracture toughness. The study also compared the cracks generated inside the structure, which showed that the ZTA without Cr2O3, facilitated a crooked crack path, whereas the addition of Cr2O3 to Al2O3-ZrO2 structure enabled cracks to be deflected and spread in an inter-granular manner.

The above-mentioned study presented the capability of Al2O3-ZrO2 that was mixed with Cr2O3 in terms of microstructure, mechanical properties, and machining capability. Meanwhile most of the study had concentrated on material properties, such as microstructure, density, fracture toughness, and hardness. However, the wear resistance of Al2O3-ZrO2-Cr2O3 structure under sliding and machining load was not well studied (Azhar et al., 2012; Singh et al., 2016; Manshor et al., 2016). Therefore, the friction properties of Al2O3-ZrO2 mixed with specific content of Cr2O3 were studied in this work. The ability of Cr2O3 to alter the density, hardness, flexural strength, and microstructure of Al2O3-ZrO2 were also analyzed. Further, to correlate between frictions and wear resistances during machining, selected samples of Al2O3-ZrO2-Cr2O3 were machine dried with AISI 1045. A comparison was made between the cutting tool made from single Al2O3 and Al2O3-ZrO2 in terms of tool life and wear mechanism to differentiate their material characteristics at high pressure and high temperature applications. 2.0 EXPERIMENTAL PROCEDURE

Specific composition of Al2O3-ZrO2 with mixing ratio of 80-20 wt% were mixed with variant Cr2O3 content at 0.2, 0.4, 0.6 and 0.8 wt%. Range of composition were selected based on the studies referred from Azhar et al. (2012). These mixtures then were ball milled before pressed by Cold Isostatic Press (CIP) at the pressure of 350 MPa. The compacted powders were sintered at constant temperature of 1400oC and 9 hours soaking time. The shape of cutting tool was prepared with 12 mm diameter and 6 mm thickness according to the code of RNGN 120600. Figure 1 shows the sequence of process flow to fabricate the cutting tools. Table 1 shows the processing parameter used to prepare the cutting tools. The density, hardness and flexural strength were measured by the Densitimeter and Vickers hardness respectively. For flexural strength evaluation, 3-point bending test was held according to sample already tested. The test was performed according to three-point bending test based on ASTM C1161-18. Universal Testing Machine (UTM) was used to measure flexural strength.

Table 1: Processing parameters to fabricate Al2O3-ZrO2 cutting tool.

Main Composition 80 wt% Al2O3 - 20 wt% ZrO2

Cr2O3 Content 0.2, 0.4, 0.6, 0.8 wt%

Ball Mill 12 hours

Sintering Temperature 1400oC with 9 hours soaking time

CIP Pressure 350 MPa


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Figure 1. The procedure to fabricate Al2O3-ZrO2-Cr2O3 cutting tool (a) Preparing the powders (b) Blending in ball mill for 12 hours (c) Inserting powders into the mould (d) Pressing the mould by hydraulic hand press (e) Green body of ceramic compact (f) Pressing the powders by Cold Isostatic Press (g) Sintering the compacted powders (h) Finish product of ceramic cutting tool after sintering with the diameter of 12 mm and thickness of 6 mmm (RNGN 120600).

For the Coefficient of Friction (COF) assessment, Micro Pin on Disk Tribotester machines, model CM-9109 was used. During pin-on-disc wear test, a pin is loaded against a flat rotating disc specimen such that a circular wear path is described by the machine, as shown in Figure 2. The specimen was loaded with 10N pressure and 1800s time interval by the pin sliding on the disc. The distance and velocity of friction were set at 3 mm and 5 mm/s respectively. Figure 3 shows an illustration of the movement of alumina pin friction on the tested ceramic cutting tool.

Figure 2: (a) Micro Pin on Disk Tribotester (b) Al2O3 ball for friction on ceramic cutting tool.


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Figure 3: Illustration of the movement of alumina pin friction.

In terms of machining test, samples that possess desired mechanical properties were

selected. The cutting tool was clamped on the CRDN N2525-42 tool holder as shown in Figure 4. AISI 1045 workpiece material with the dimension of 50 mm diameter and 250 mm length was prepared inside HAAS SL20 CNC turning machine. The machining trials was held at 200 m/min, 0.175 mm/rev and 0.5 mm depth of cut. The tool wear was measured by using toolmaker microscope with VB at 0.3 mm according to the ISO 3685 guideline. The worn cutting tool was observed under Scanning Electron Microscope (SEM) for wear mechanism analysis. Figure 4 shows the setup for the machining test.

Figure 4: Machining set up for tool wear test.

3.0 RESULTS AND DISCUSSION

Figure 5 (a-b) shows the effect of Cr2O3 content on the relative density and hardness, respectively. Analysis from Figure 5(a) shows that the addition of 0.2 wt% Cr2O3 demonstrated the highest relative density of 101.07%. This was followed by 0.4 wt% Cr2O3 addition for 100.66% relative density. The relative density decreased to 95.81% and 94.85% when 0.6 wt% and 0.8 wt% Cr2O3 were added to the Al2O3-ZrO2 composition, respectively. Analysis from Figure 5(b) shows that the hardness test demonstrated opposite results as compared to the density result. The hardness increased from 66.2 HRC to 71.03 HRC as the Cr2O3 content was increased from 0.2 to 0.6 wt%. However, when the Cr2O3 content was further increased to 0.8 wt%, the hardness slightly declined to 70.9 HRC. This showed that the crucial value for Cr2O3 addition was 0.6 wt%.


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Figure 5: (a) Effect of Cr2O3 content on the hardness (b) Effect of Cr2O3 content on the hardness

Figure 6: (a) Effect of Cr2O3 content on the flexural strength (b)Effect of Cr2O3 content on the coefficient of friction (COF).

Figure 6(a) shows the effect of Cr2O3 content on the flexural strength for cutting tool fabricated by 80 wt% Al2O3 and 20 wt% ZrO2. Results of the flexural strength test were in-line with the results of the hardness test performed. The addition of 0.6 wt% Cr2O3 still dominated the highest results, which was recorded at 988.27 MPa. This was followed by the addition of Cr2O3 at 0.8 wt%, 0.4 wt%, and 0.2 wt% to provide a flexural strength of 960.74 MPa, 787.71 MPa, and 316.91 MPa respectively. Manshor et al., (2016) also investigated the effects of Cr2O3 on Al2O3 -based cutting tool. The study also found that the addition of 0.6 wt% of Cr2O3 provided the highest proportion to produce high hardness, tensile strength, and thermal shock resistance of Al2O3 -based cutting tool, similar to this study.

Figure 6(b) shows the effect of Cr2O3 content on the coefficient of friction (COF) under a normal load of 10N within 1800 s. Low COF of 0.2 was recorded at the lowest content of Cr2O3 (0.2 wt%). As the Cr2O3 was increased to 0.6 wt%, the COF was decreased to 0.23. However, the addition of 0.8 wt% provided the maximum COF at 0.29.

The results from Figure 5(a) showed that the addition of Cr2O3 to Al2O3-ZrO2 had a negative effect on density. According to Hirata et al., (2000), the deterioration of density could be due to evaporation, in which Cr2O3 that was added to the Al2O3-ZrO2 was dissolved when the sintering


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process was carried out. This could leave some porosity whenever the Cr2O3 was evaporated during sintering.

On the other hand, the hardness and flexural strength increased as the Cr2O3 content increased, except for 0.8 wt%, as shown in the Figure 5(b) and Figure 6(a). In terms of COF, the addition of 0.6 wt% provided a low COF at 0.23, which represented the sliding wear resistance of ceramic surface, as shown in Figure 6(b). Since Cr2O3 was expected to be evaporated during sintering, this vaporized Cr2O3 could be heterogeneously distributed to the upper surface area of Al2O3-ZrO2. Since Cr is hardly soluble in ZrO (Magnani & Brillante, 2005) the Cr ions should be dissolved and diffused through the surface of Al2O3. The dissolution of Cr on selected Al2O3 particles promoted faster grain growth because of the coherency strain energy at the grain boundary. This resulted in the formation of surface anisotropy along the upper surface area of Al2O3-ZrO2 (Doh et al., 2000; Hernandez et al., 2003, Magnani & Brillante, 2005).

With respect to anisotropy distribution at the upper surface area of Al2O3-ZrO2, the resistive shear stress will control hardness on various directions as a result of slip resistance improvement on the grain boundary (Blanda et al., 2014). In addition, anisotropic of grains will result in toughening mechanism which deflected cracks propagation direction along the grain boundaries (Oungkulsolmongkol et al., 2010). Finally, the anisotropy phenomena at the upper layer of surface contributed to high hardness, flexural strength and reduced COF. In this study, it was expected that the addition of Cr2O3 of up to 0.6 wt% produced the desired anisotropy characteristics of the surface, especially at the region around the surface area.

Figure 7 shows the comparison of microstructure for pure Al2O3, Al2O3-ZrO2 and Al2O3-ZrO2-Cr2O3 cutting tools. Pure Al2O3 cutting tool (Figure 7(a)) presented an uneven grain structure with clear porosity, which indicated incomplete compaction of the cutting tool grain structure. As compared to the Al2O3-ZrO2 cutting tool (Figure 7(b)), the grain structure appeared in better compaction, whereby the grain neck presented strong attachment in some locations. However, there was still a significant appearance of porosity. For Al2O3-ZrO2-Cr2O3 cutting tool (Figure 7(c)), the addition of Cr2O3 to Al2O3-ZrO2 had significantly improved the grain compaction. The grains presented stronger particle bonding to reflect better integrity to resist particle detachment when applied with a load.

Figure 7: Microstructure comparison between (a) Al2O3, (b) Al2O3-ZrO2 and (c) Al2O3-ZrO2-Cr2O3.

Since the sample that contained Al2O3-ZrO2-Cr2O3 with the mixing ratio of 80-20-0.6 wt% presented better mechanical properties and lower COF, this sample was selected to be compared with Al2O3 and Al2O3-ZrO2 for coefficient of friction and machining wear performance. Figure 8 shows the COF of Al2O3, Al2O3-ZrO2, and Al2O3-ZrO2-Cr2O3 under a normal load of 10N within


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1800s. It was observed that a steady state friction coefficient (COF) was attained after 1800s sliding time. Obviously, the surface of Al2O3-ZrO2-Cr2O3 presented lower COF (0.23) as compared to Al2O3-ZrO2 (0.29) and Al2O3 (0.35). Although a steady state value of the friction coefficient is well defined for Al2O3 and Al2O3-ZrO2, the oscillations of around the average value were noticeable. According to Mora et al., 2017, this behavior was attributed to the presence of local roughness variations on the material surface due to the occurrence of pull-outs of Al2O3 grains.

Figure 8: Comparison of coefficient of friction for Al2O3, Al2O3-ZrO2 (80-20 wt%) and Al2O3-ZrO2-Cr2O3 (80-20-0.6 wt%).

It should be noted that high COF value of single Al2O3 structure reflected low wear resistance when exposed to the sliding load. Single phase of Al2O3 alone was unable to withstand the sliding load from friction test to provide the maximum COF of cutting tool at 0.35. The brittle nature of the Al2O3 properties cannot survive longer sliding test. Al2O3-ZrO2 provided better improvements, whereby the COF obtained was lower than Al2O3 at 0.29. Strong bonding between Al2O3 and ZrO2 grains contributed to the reinforcement structure that was capable to resist deformation whenever the sliding load was applied. On the other hand, the Al2O3-ZrO2-Cr2O3 exhibited the lowest COF of 0.23, which presented the highest wear resistance to the sliding load.

Figure 9 shows the comparison of wear development for Al2O3-ZrO2-Cr2O3, Al2O3-ZrO2, and Al2O3 cutting tools at 200 m/min cutting speed, 0.175 mm/rev feed rate, and 0.5 mm depth of cut. The graphs demonstrated a linear trend of tool wear development for each cutting tool. The performance of Al2O3-ZrO2-Cr2O3 cutting tool recorded maximum tool life up to 247 s, whereas Al2O3-ZrO2 cutting tool only lasted for 164 s while Al2O3 cutting tool only performed at an estimate of 25 s due to breakage at the early stage of machining.


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Figure 9: Wear development for the fabricated cutting tools when machining with AISI 1045 at 200 m/min cutting speed, 0.175 mm/rev feed rate and 0.5 mm depth of cut.

Figure 10 shows the comparison of wear mechanisms between Al2O3, Al2O3-ZrO2, and Al2O3-ZrO2-Cr2O3 cutting tools. For Al2O3 cutting tool (Figure 10(a)), forms of severe chipping and fracture were clearly seen at the contact area with workpiece. The cutting edge presented serious breakage that facilitated catastrophic failure within a few seconds of machining. For Al2O3-ZrO2 cutting tools (Figure 10(b)), there was a little notch at the side of the cutting point. Sign of material loss at the rake face showed that the machining could induce chatter and vibration which can be devastating to the tool edge as machining was prolonged. This showed that even though the ZrO2 was already added to the Al2O3 sturcture, there was still evidence of brittleness at the cutting edge. Minor built-up edge was clearly visible on the edge of the cutting tool. In contrast, machining with Al2O3-ZrO2-Cr2O3 cutting tool demonstrated a uniform flank wear and still presented a sharp nose radius to make the cutting process still feasible, as shown in (Figure 10(c)). The wear presented by Al2O3-ZrO2-Cr2O3 cutting tool which still appeared in clean condition reflected that low graduation rate was subsequent to the lower friction inside the cutting zone.

Figure 10: Wear mechanism for the fabricated cutting tools a) Al2O3 b) Al2O3-ZrO2 and c) Al2O3-ZrO2-Cr2O3.


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Since Al2O3 cutting tool possess brittle characteristics, single alumina alone was unable to resist the load from machining. As a result, the cutting tool experienced a tremendous catastrophic failure when engaged with the workpiece materials. Since single Al2O3 had high COF of 0.35, which reflected low wear resistance, the grains experienced spalling fatigue when exposed to the cutting load (Zehua et al., 2014). As the machining prolonged, the breakage of Al2O3 is unavoidable since the impact from the rotational workpiece seems to exceed the strength of the cutting tool.

When Al2O3-ZrO2 performed to machine AISI 1045, the cutting tool demonstrated the capability to machine up to 500% improvement as compared to the singe Al2O3, which represented better structural integrity of Al2O3-ZrO2. However, there was evidence of minor adhesive wear which appeared at the specific region of cutting tool, as shown in Figure 10(b). Adhesive wear occurred when particles of cutting tool were removed by the molten metal that diffused into the cutting tool structure. This adhesive wear facilitated better particle plucking of cutting tool, assisted by the heat generated at the specific area. Even though the addition of 20%wt of ¬ZrO2 to the Al2O3 structure provided lower COF, the existence of heat diminished their toughening structure. As the machining was prolonged, more material loss occurred at the adhesive region, resulting in more friction and higher cutting force due to the ununiformed cutting edge. Hence the strength of the edge of the cutting tool started to deteriorate, resulting in more chipping and fracture of the cutting tool until it reached tool life.

As the Al2O3-ZrO2-Cr2O3 performed to machine AISI 1045, the tool life was increased at 51% as compared to the Al2O3-ZrO2 and improved almost 800% as compared to the Al2O3. The addition of Cr2O3 had reportedly enhanced the Al2O3 grain growth to facilitate better particle compaction that yielded higher density, flexural strength, and hardness (Azhar et al., 2012). In addition, the particle of zirconia that was trapped between the expanded alumina particles provided particle interlocking at the grain boundary. When this structure was exposed to the cutting load, the interlocked particles increased the graduation resistance to resist deformation and load, resulting in lower friction and better wear resistance at the cutting region.

4.0 CONCLUSIONS

This paper presents the friction and wear evaluation of ceramic cutting tools based on the composition of Alumina (Al2O3), Zirconia (ZrO2) and Chromia (Cr2O3). The properties of hardness, density, flexural strength, coefficient of friction and machining wear performance were assessed to evaluate the effect of Cr2O3 content on mechanical properties and differentiate the properties of Al2O3, Al2O3-ZrO2 and Al2O3-ZrO2-Cr2O3. Based on the experimental results, the following conclusions can be drawn: -

1. Ceramic compacts fabricated from Al2O3-ZrO2-Cr2O3 with the mixing ration of 80-20-0.6 wt% demonstrated maximum hardness and flexural strength of 71.03 HRC and 988.07 MPa.

2. The density decreased when the content increased due to vaporization of Cr2O3 during sintering. Maximum relative density recorded at 101.87 % while minimum density recorded at 94.85 %.

3. Microstructure of Al2O3-ZrO2-Cr2O3 presenting significant grains compaction as compared to Al2O3-ZrO2 and single Al2O3 that showed significant appearance of porosity.

4. Coefficient of Friction for Al2O3-ZrO2-Cr2O3 with 80-20-0.6 wt% composition recorded minimum value at 0.23 representing lowest sliding wear resistance. Al2O3-ZrO2 and single Al2O3 cutting tools recorded higher Coefficient of Friction of 0.29 and 0.35 respectively.


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5. The Al2O3-ZrO2-Cr2O3 cutting tool developed manage to perform up to 247 s tool life when machined with AISI 1045 at the 200 m/min cutting speed, 0.175 mm/rev feed rate and 0.5 mm depth of cut. This is 51% and 800% better tool life than Al2O3-ZrO2 and Al2O3 cutting

tools. Tool life for Al2O3-ZrO2 and single Al2O3 cutting tools recorded 164s and 25s respectively.

6. The wear mechanism for Al2O3-ZrO2-Cr2O3 cutting tool started with small notch wear at the specific region, For Al2O3-ZrO2 and single Al2O3 cutting tools, the wear mechanism dominated by the adhesive wear and severe chipping.

ACKNOWLEDGEMENT

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friction and wear analysis of ceramic cutting tool made ... · muhammad hafiz hassan 3 1 centre of...

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