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Friction and wear analysis of ceramic cutting tool made from Alumina-Zirconia-Chromia

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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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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: hadzley@utem.edu.my
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.
Jurnal Tribologi 24 (2020) 27-38
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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
Jurnal Tribologi 24 (2020) 27-38
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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.
Jurnal Tribologi 24 (2020) 27-38
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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
Jurnal Tribologi 24 (2020) 27-38
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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
Jurnal Tribologi 24 (2020) 27-38
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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
The authors would like to thank Faculty of Manufacturing Engineering and Universiti Teknikal
Malaysia Melaka (UTeM) for their support that enabled this work to be carried out through the
grant of FRGS/1/2017/TK03/FKP-AMC/F00341.
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... In [17], the study focused on the analysis of friction and wear of ceramic cutting tools made from Al 2 O 3 , ZrO 2 , and Cr 2 O 3 . The tool was manufactured at machine AISI 1045. ...
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