Research Projects

Firstly, predominant use of carbide and coated carbide inserts in manufacturing industries is expected to be impeded due to the high demand of the constituent elements, nickel and cobalt, in strategic sectors and electric vehicle technology. Therefore, Industries are searching for an alternate material as cutting inserts. Secondly, environment-friendly disposal of cutting fluid is also a major issue faced by the manufacturing industries. So currently they are shifting towards sustainable eco-friendly machining without use of lubricants. Thirdly, post-machining grinding is needed to meet surface finish requirement of the produced part after turning. In recent era, manufacturers are trying to opt for one step turning process with desired surface finish, thus eliminating extra grinding operations. All these major issues can be addressed using a ceramic tool such as zirconia toughened alumina (ZTA). However, low fracture toughness impedes its use. To improve toughness, addition of MAX/MXene in ZTA matrix is an alternative and effective approach for developing a novel composite. Superior thermal stability, high toughness, plastic deformation as well as stiffness, and self-lubricating behaviour of MAX/MXene phase materials will address the constraints of conventional ZTA ceramics. MAX phase materials are a new class of ternary carbide/nitride layered structures having good mechanical as well as thermal properties. A derived product of MAX, 2D MXene, consists of atomically thin layers has attracted the researcher’s attention. It is considered as emerging solid lubricating materials. The unique combination of metallic and surface characteristics endows MXene a promising materials for improving mechanical as well as tribological properties of ceramics. However, major challenges for MAX/MXene ZTA composites are (a) dispersion of MAX/MXene phase into ZTA matrix, (b) optimized wt.% of MAX/MXene reinforcement and (c) pressure assisted sintering in a controlled atmosphere. In this project, after synthesizing in laboratory, different wt.% of MAX/MXene will be mixed into ZTA. Pressure assisted sintering (HP/SPS) will be used for composite preparation where various parameters will be optimized for suitable mechanical and tribological properties. Finally, the developed material will be used for cutting insert fabrication. The performance of the cutting inserts will be accessed by the cutting force generated, flank wear of the inserts, surface finish of the job etc. The eco-friendly machining i.e. turning without any lubricant will be attempted while machining steel and performance will be compared with carbide/coated carbide inserts in high speed machining application. An attempt will be made to get best surface finish of the job by tuning the machining parameters i.e. cutting speed, feed rate and depth of cut and the conditions will be optimized with an aim to maximum tool life with minimum tool failures.