Using Ceramic Inserts in Hard Turning

In metalworking, there are a myriad of indexable insert types and geometries available for use in any given application. Many of them have proven to reduce production costs, improve part quality and simplify changing the cutter over time in shops of all sizes. However, when it comes to cutting hard materials such as nickel-based super alloys or weld clad metals, ceramic inserts are a solid option for reducing cycle times and improving the overall machining process.

But while the advantages of using ceramics are numerous, their high hardness often translates to extreme brittleness. This can cause early insert breakage, which is one of the main reasons why some manufacturers shy away from ceramics. But with a little knowledge, and the right machining techniques, using ceramics in hard turning can be a profitable endeavor for any shop.

While the selection of a proper insert grade is important, the edge preparation and hone is crucial when it comes to ceramics. He advises choosing a grade that is suitable for the specific material being machined and utilizing the appropriate hone size and k-land to maximize performance. He also recommends implementing ramping methods which help eliminate deep-of-cut chipping and notching.

Ceramic inserts perform very well in the range of 50 to 55 HRC and provide cutting data comparable to CBN, while allowing for higher spindle speeds. This allows users to machine difficult-to-cut material such as Waspaloy and Inconel 718 up to 5-7 times faster than conventional carbide grades. Ceramics also tend to have a longer tool life than carbide, and are significantly less expensive.

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