Abstract
Manufacturability of advanced ceramics has been a challenging issue mainly because of their brittle behaviors and high hardness. One approach to solving this issue is enabling ductile regime cutting, which can also be used to enhance the quality of the surface and accuracy of the final product. There have been many studies investigating how to control and prolong the ductile response regime during cutting; however, it still lacks a straightforward explanation that enables us to predict the transition of the material response from the ductile regime to the brittle regime. In this study, the processing of monocrystalline yttria-stabilized zirconia was investigated to predict material behavior during cutting. Here, it is aimed to confirm that stress intensity factor analysis can be applied with a wide variety of process parameters and investigate the effect of varying the process parameters on the ductile–brittle material response transition. Experimental results showed that negative rake angle and higher cutting speed prolonged the ductile cutting regime. However, the cutting stress at the ductile–brittle transition point remained constant regardless of the process parameters which enabled us to predict the transition point with respect to the stress intensity factor. It is expected that the results of this research can contribute to the development of machining strategies with improved throughput and thus to increasing the utilization of ceramic materials.
Similar content being viewed by others
References
Liu, Z. Y., Huang, C., Zhao, Y., & Guo, Y. B. (2017). Kinematic modeling and deformation mechanics in shot peening of functional ceramics. International Journal of Advanced Manufacturing Technology, 93(5–8), 1669–1683. https://doi.org/10.1007/s00170-017-0661-y.
Ferraris, E., Vleugels, J., Guo, Y., Bourell, D., Kruth, J. P., & Lauwers, B. (2016). Shaping of engineering ceramics by electro, chemical and physical processes. CIRP Annals, 65(2), 761–784. https://doi.org/10.1016/j.cirp.2016.06.001.
Anselmi-Tamburini, U., Woolman, J. N., & Munir, Z. A. (2007). Transparent nanometric cubic and tetragonal zirconia obtained by high-pressure pulsed electric current sintering. Advanced Functional Materials, 17(16), 3267–3273. https://doi.org/10.1002/adfm.200600959.
Hannink, R. H. J., Kelly, P. M., & Muddle, B. C. (2000). Transformation toughening in zirconia-containing ceramics. Journal of the American Ceramic Society, 83(3), 461–487. https://doi.org/10.1111/j.1151-2916.2000.tb01221.x.
Schelling, P. K., Phillpot, S. R., & Wolf, D. (2001). Mechanism of the cubic-to-tetragonal phase transition in zirconia and yttria-stabilized zirconia by molecular-dynamics simulation. Journal of the American Ceramic Society, 84(7), 1609–1619. https://doi.org/10.1111/j.1151-2916.2001.tb00885.x.
Pfefferkorn, F. E., Shin, Y. C., Tian, Y., & Incropera, F. P. (2004). Laser-assisted machining of magnesia-partially-stabilized zirconia. Journal of Manufacturing Science and Engineering, 126(1), 42–51. https://doi.org/10.1115/1.1644542.
Pashmforoush, F., & Esmaeilzare, A. (2017). Experimentally validated finite element analysis for evaluating subsurface damage depth in glass grinding using Johnson-Holmquist model. International Journal of Precision Engineering and Manufacturing 18(12), 1841–1847. https://doi.org/10.1007/s12541-017-0213-2.
Neo, W. K., Kumar, A. S., & Rahman, M. (2012). A review on the current research trends in ductile regime machining. International Journal of Advanced Manufacturing Technology, 63(5–8), 465–480. https://doi.org/10.1007/s00170-012-3949-y.
Maas, P., Mizumoto, Y., Kakinuma, Y., & Min, S. (2017). Machinability study of single-crystal sapphire in a ball-end milling process. International Journal of Precision Engineering and Manufacturing 18(1), 109–114. https://doi.org/10.1007/s12541-017-0013-8.
Zhang, G., Zeng, Y., Zhang, W., Zhou, H., Wen, Z., & Yao, Y. (2016). Monitoring for damage in two-dimensional pre-stress scratching of SiC ceramics. International Journal of Precision Engineering and Manufacturing 17(11), 1425–1432. https://doi.org/10.1007/s12541-016-0168-8.
Chen, J. B., Fang, Q. H., Wang, C. C., Du, J. K., & Liu, F. (2016). Theoretical study on brittle–ductile transition behavior in elliptical ultrasonic assisted grinding of hard brittle materials. Precis Engineering 46, 104–117. https://doi.org/10.1016/j.precisioneng.2016.04.005.
Venkatachalam, S., Li, X., & Liang, S. Y. (2009). Predictive modeling of transition undeformed chip thickness in ductile-regime micro-machining of single crystal brittle materials. Journal of Materials Processing Technology, 209(7), 3306–3319. https://doi.org/10.1016/j.jmatprotec.2008.07.036.
Arif, M., Xinquan, Z., Rahman, M., & Kumar, S. (2013). A predictive model of the critical undeformed chip thickness for ductile–brittle transition in nano-machining of brittle materials. International Journal of Machine Tools and Manufacture 64, 114–122. https://doi.org/10.1016/j.ijmachtools.2012.08.005.
Mizumoto, Y., Maas, P., Kakinuma, Y., & Min, S. (2017). Investigation of the cutting mechanisms and the anisotropic ductility of monocrystalline sapphire. CIRP Annals, 66(1), 89–92. https://doi.org/10.1016/j.cirp.2017.04.018.
Yoon, H.-S., Kwon, S. B., Nagaraj, A., Lee, S., & Min, S. (2018). Study of stress intensity factor on the anisotropic machining behavior of single crystal sapphire. CIRP Annals, 67(1), 125–128. https://doi.org/10.1016/j.cirp.2018.04.114.
Yoon, H.-S., Lee, S., & Min, S. (2018). Investigation of ductile-brittle transition in machining of yttrium-stabilized zirconia (YSZ). In Procedia Manufacturing, 46th SME North American manufacturing research conference, NAMRC 46, Texas, USA (Vol. 26 , pp. 446–453). https://doi.org/10.1016/j.promfg.2018.07.052.
Pajares, A., Guiberteau, F., Dominguez-Rodriguez, A., & Heuer, A. H. (1988). Microhardness and fracture toughness anisotropy in cubic zirconium oxide single crystals. Journal of the American Ceramic Society, 71(7), 332–333. https://doi.org/10.1111/j.1151-2916.1988.tb05933.x.
Günay, M., Aslan, E., Korkut, I., & Seker, U. (2004). Investigation of the effect of rake angle on main cutting force. International Journal of Machine Tools and Manufacture, 44(9), 953–959. https://doi.org/10.1016/j.ijmachtools.2004.01.015.
Kienzle, O., & Victor, H. (1957). Spezifische Schnittkräfte bei der Metallbearbeitung. Werkstattstechnik und Maschinenbau, 47(5), 224–255.
Grossi, N. (2017). Accurate and fast measurement of specific cutting force coefficients changing with spindle speed. International Journal of Precision Engineering and Manufacturing 18(8), 1173–1180. https://doi.org/10.1007/s12541-017-0137-x.
Yoon, H.-S., Wu, R., Lee, T.-M., & Ahn, S.-H. (2011). Geometric optimization of micro drills using Taguchi methods and response surface methodology. International Journal of Precision Engineering and Manufacturing 12(5), 871–875. https://doi.org/10.1007/s12541-011-0116-6.
Kim, C.-J., Mayor, R., & Ni, J. (2012). Molecular dynamics simulations of plastic material deformation in machining with a round cutting edge. International Journal of Precision Engineering and Manufacturing 13(8), 1303–1309. https://doi.org/10.1007/s12541-012-0173-5.
Luo, S., Bayesteh, A., Ko, J., Dong, Z., & Jun, M. B. (2017). Numerical simulation of chip ploughing volume in micro ball-end mill machining. International Journal of Precision Engineering and Manufacturing, 18(7), 915–922. https://doi.org/10.1007/s12541-017-0108-2.
Blake, P. N., & Scattergood, R. O. (1990). Ductile-regime machining of germanium and silicon. Journal of the American Ceramic Society, 73(4), 949–957. https://doi.org/10.1111/j.1151-2916.1990.tb05142.x.
Chen, X., Xu, J., Fang, H., & Tian, R. (2017). Influence of cutting parameters on the ductile-brittle transition of single-crystal calcium fluoride during ultra-precision cutting. International Journal of Advanced Manufacturing Technology, 89(1–4), 219–225. https://doi.org/10.1007/s00170-016-9063-9.
Yan, J., Syoji, K., Kuriyagawa, T., & Suzuki, H. (2002). Ductile regime turning at large tool feed. Journal of Materials Processing Technology, 121(2–3), 363–372. https://doi.org/10.1016/S0924-0136(01)01218-3.
Wang, J.-J. J., & Liao, Y.-Y. (2007). Critical depth of cut and specific cutting energy of a microscribing process for hard and brittle materials. Journal of Engineering Materials and Technology, 130(1), 011002–011002–6. https://doi.org/10.1115/1.2806253.
Acknowledgements
Authors gratefully acknowledge kind support from the FANUC Corporation, Japan, for the loan of the 5-axis ultra-precision machine tool, ROBONANO α-0iB, and A.L.M.T. Corp., Japan, for providing PCD tools to MIN LAB at UW-Madison. This work was also supported by the National Research Foundation of Korea (NRF) grant funded by the Ministry of Education, Science and Technology (Nos. NRF-2018R1C1B5085752 and NRF-2016R1A6A3A03012011), and 2018 Korea Aerospace University Faculty Research Grant.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Yoon, HS., Kwon, S.B., Nagaraj, A. et al. Investigation of the Ductile Cutting Behavior of Monocrystalline Yttria-Stabilized Zirconia During Ultra-Precision Orthogonal Cutting. Int. J. Precis. Eng. Manuf. 20, 1475–1484 (2019). https://doi.org/10.1007/s12541-019-00150-9
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-019-00150-9