Finite element analysis and wear mechanism of B4C–TiB2 ceramic tools in turning AISI 4340 workpieces

Abstract In this study, B4C–TiB2 composite ceramics with different TiB2 contents sintered via hot pressing are processed into ceramic tools to turn AISI 4340 workpieces. Finite element analysis using the Deform-3D software is conducted to examine the effects of the cutting speed, depth of cut, and feed rate on the main cutting force and tool temperature of the B4C–TiB2 ceramic tools. The wear mechanism is investigated through the microstructural analysis of the wear profile obtained after the turning experiments. Simulation results show that the B4C–30%TiB2 ceramic tool demonstrates the best cutting performance. The optimal cutting parameters for the B4C–30%TiB2 ceramic tool are a cutting speed of 300 m/min, depth of cut of 0.3 mm, and feed rate of 0.1 mm/r. The turning experiments reveal that the B4C–30%TiB2 ceramic tool has a longer tool life than a commercially available YD tungsten carbide tool. The main wear forms of the B4C–30%TiB2 ceramic tool are craters, chipping, and flank wear, and the wear mechanism can be attributed mainly to abrasive wear, adhesive wear, oxidative wear, and diffusion wear. This work can lay a theoretical foundation for the practical application of B4C–TiB2 ceramic tools.