Geometric Structures for Sialon Ceramic Solid End Mills and Its Performance in High-Speed Milling of Nickel-Based Superalloys

Sialon ceramic tool material has become one of the most ideal materials for the high-speed cutting of superalloy materials. However, studies on the geometric structure of sialon ceramic solid end mill is lacking at the present. In this work, the geometric structure of sialon ceramic end mills was designed for difficult-to-machine nickel-based superalloy materials. The cutting force and heat, flank wear and machined surface quality were analyzed to study the effect of the main parameters on tool performance. The results showed that the end mill experienced severe flank wear and chipping, which were the leading cause of its failure during high-speed cutting. The cutting force and temperature decreased gradually with the increase in the helix angle. With the increase in the rake angle, the flank wear and the quality of the machined surface of the specimen first decreased and then increased. With the increase in the relief angle, the cutting temperature of the ceramic end mill gradually decreased, and the cutting force and the machined surface roughness showed an initial decrease and then increased. When the helix angle, rake angle and relief angle were 35 degrees, -15 degrees and 12 degrees, respectively, the sialon ceramic end mill exhibited the best cutting performance and obtained better machined surface quality in the nickel-based superalloys.