Ceramic Turning Insert in Hard Material Machining

A ceramic turning insert in hard material machining offers the potential for higher metal removal rates, improved tool life and reduced cycle times. Its inherent properties of being hard and chemically stable provide machinists with a much more productive alternative to carbide inserts in many applications. Powder metallurgy advancements enable production of extra-hard sintered ceramic grades that can exceed the hardness of coated carbide. The new grades are designed to resist microchatter that causes flank wear in a variety of materials, especially hardened steel, cast iron and nickel-based alloys.

The new grade inserts also withstand greater cutting temperatures than their predecessors. They come in a variety of geometries for milling and turning, including positive geometry that works best on close tolerance parts and thin-walled components. They are available with a range of coatings to resist abrasion, increase speed and reduce tool costs.

In addition to avoiding excessive feeds and speeds, machinists using ceramic inserts must ensure the machine, part and toolholder are rigid. The stiffest holder possible and one with a thicker shank or boring bar diameter will help reduce vibrations that can damage the insert and cause a poor surface finish of the workpiece. If the machinist plans to use multiple roughing passes, the programmer should consider varying the depth of cut on each pass. Multiple successive passes at the same depth tend to wear the insert in the same area causing a notch to form. Varying the depth spreads the wear patterns over a larger area of the insert and helps to extend tool life.

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