Deliverables Modelling and wear investigation Modelling of the SiAlON material and wear mechanisms regarding the relationship between a / ß SiAlON proportions, the type and degree of wear have been performed. ESIL developed a microstructure sub model approach for determination of the stress distribution within the microstructure with focus on particle size and relation between different phases. Furthermore, an assessment was made to see how the microstructure design influences the flank wear on the cutting tool. Hardness and toughness test simulations have been performed to predict the appropriate material properties. An assessment has been made of the stresses and temperatures at the cutting interface More information on the FGMSIATOOL-project can be found at http://www.arcs.ac.at/FGMSIATOOL Cutting tests results superior to commercial inserts for FGM SiAlON and new SiAlON pieces Preliminary cutting tests were performed at ARC, CRF and SGAC. CRF and SGAC carried out wet and dry machining test on different "difficult to cut" ferrous-based materials in order to study and classify wear mechanisms for commercial competing ceramic inserts. Collected data have been also used as input for tool wear simulation in co-operation with ESIL. The first prototypes of the FGM inserts performed very good results in the rough turning of ADI Cast Iron and Inconel 718 using the same cutting parameters of the production plants at CRF. A qualitative analysis allows to estimate a reduction in tool wear around 25 with respect to the tested best competing commercial inserts. The results will not be industrialised because the special process is not scalable in manufacture facility. Cutting experiments with the new SiAlON grade inserts out of laboratory gave good performance: in tests with ADI cast iron and spherical graphite cast iron. The new grade A3 and A4 have been tested in cutting (turning) and face milling. Cutting of ADI was not so successful but face milling of hardened steel M2 gave 600% increase in cutting speed and 100% in feed. More information on the FGMSIATOOL-project can be found at http://www.arcs.ac.at/FGMSIATOOL Searching for OpenAIRE data... There was an error trying to search data from OpenAIRE No results available
