A very helpful from our friends at NTK Cutting Tools.
When you hear the word “ceramic”, the first thing people may think of is the “white” material used for plates and sanitary ware (toilets).
But that type of ceramic is just one of a number of ceramics. There are as many as ﬁve ceramics used for cutting tools.In this article, we will introduce the 5 types of ceramic used in cutting tools.
What is ceramic in the ﬁrst place?
IIn a broad sense, ceramics are a blend of metal or nonmetal with oxygen (O), nitrogen (N), carbon (C), etc., and this baked material is used as a cutting tool.
The ceramic used in cutting tools is roughly available in two types of “Alumina ceramic” (Al2O3) and “silicon nitride (Si3N4) ceramic” made by blending various additives with the main ingredients to develop specific characteristics.
It is further subdivided by the addition of various additives to the main ingredients.
Al2O3 : Alumina-based ceramics
1. White Ceramic
Alumina (Al2O3) is the main component of ceramic, and is called white ceramic because of its color. In fact, the same ingredients are in jems like rubies and sapphires (Al2O3)
The main difference is that ruby and sapphire are single crystals (particles of one large mass), while alumina is polycrystalline (a collection of multiple particles). Alumina is hard and chemically stable. Taking advantage of its properties, it is used in high-speed finishing of cast iron.
2. Black Ceramic
Titanium carbide (TiC) is added to alumina, and this is called black ceramic because of its color.
The addition of titanium carbide results in higher hardness, than white ceramic, and suppresses deformation of the cutting edge due to heat; even at high temperatures.
Taking advantage of its properties, it is used in high-speed finishing of hardened materials up to about HRC65.
It is a ceramic in which silicon carbide (SiC) is added to alumina. Do you know why it’s called whisker ?
Silicon carbide has a needle-like shape similar to a “animal beard”, so it is now called whisker (ceramic).
By intertwining silicon carbide with each other, the progression of cracks due to impacts during cutting is suppressed, and cracks are prevented. In addition, it has a resistance against sudden temperature changes. Taking advantage of these properties, it is widely used for heat-resistant alloy processing.
Silicon nitride, Si3N4
5. Silicon Nitride
Silicon nitride (Si3N4) is the main component, and a special feature is that the particles are needle-like, different from the alumina compound.
By intertwining needle-like particles, the progression of cracks due to impact during cutting can be greatly suppressed, preventing cracks.
Taking advantage of these properties, it is used in high-speed roughing of cast iron.
Silicon nitride (Si3N4), Aluminum (Al), and oxygen (O)are blended to form SiAlON, which is an initial of its component elements.
Sialons, like silicon nitride, have needle-like particles. Needle-like particles intertwine to withstand impact during cutting.
In addition, the effect of the added alumina component improves heat resistance over silicon nitride, and has excellent high temperature resistance characteristics.
Taking advantage of these properties, it is used in high-speed processing of heat-resistant alloys.
The table below shows typical machining application examples of ceramic cutting tools.
We hope this column gave you a better understanding of the types, differences, and features of ceramic materials.
Ceramic cutting tools must be used according to the material to be machined, but they can be processed up to 20 times faster than carbide tools. Increase productivity with ceramic cutting tools for your material applications.
We are very excited to announce that we are now able to offer on-site technical training to YOUR machinists at YOUR location! This is offered at no charge to customers who use any of the manufacturer's whom we represent in California and Nevada.
However, just because you don't purchase things from us, don't feel left out! We also offer on-site topic specter training on any of the following topics for $150/hour.
Each presentation lasts about 2 hours. The presentations last approximately 45-60 minutes with the remaining time for Q&A and discussion about unique applications in your facility.
Training Classes Available:
Advanced Part Manufacturing:
NTK's industry leading line of ceramic cutting tools recently expanded with new solid CERAMIC end mills! You can see our product announcement here: NTK now offers SX9 Ceramic End Mills for Cutting Exotic Alloys which contains the various features. Below is the technical info on how to run the NTK Ceramic End mills and a troubleshooting guide.
NTK's SX9 cermaic end mill grade can run at speeds of 2000 SFM. The line-up includes 4 and 6 flutes in inch and metric versions. Again, you can learn more about on our Blog Post.
Solid ceramic end mills are made with SX9 SiAlON grade substrate which features a balance of toughness and wear resistance. It's suitable for even the most demanding applications.
First Step Machining Procedures
Gernarel Recomendations for machining heat resistant alloys & PH stainless steel
As with any other techncial questions please get in touch with us on our CONTACTS page and we can provide both over-the-phone troubleshooting or schedule at time for on-site techncial training.
Technical Support Blog
At Next Generation Tool we often run into many of the same technical questions from different customers. This section should answer many of your most common questions.
We set up this special blog for the most commonly asked questions and machinist data tables for your easy reference.
If you've got a question that's not answered here, then just send us a quick note via email or reach one of us on our CONTACTS page here on the website
Our technical section is written by several different people. Sometimes, it's from our team here at Next Generation Tooling & at other times it's by one of the innovative manufacturer's we represent in California and Nevada.
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