Research Projects

The use of carbide and coated carbide inserts in manufacturing industries is expected to be impeded due to high demand for nickel and cobalt in strategic sectors and electric vehicle technology. Industries are shifting towards sustainable eco-friendly machining without lubricants and post-machining grinding to meet surface finish requirements. To address these issues, ceramic tools like zirconia toughened alumina (ZTA) can be used, but low fracture toughness hinders their use. To improve toughness, MAX or MXene phase materials can be added to ZTA matrix, offering superior thermal stability, high toughness, plastic deformation, stiffness, and self-lubricating behavior. However, major challenges for MAX or MXene ZTA composites include dispersion of MAX or MXene phase into ZTA matrix, optimized reinforcement, and pressure assisted sintering in a controlled atmosphere. This project aims to synthesize MAX or MXene in ZTA, mix different wt.% of MAX or MXene, and use pressure assisted sintering for composite preparation. The developed material will be used for cutting insert fabrication, focusing on cutting force, flank wear, and surface finish. Eco-friendly machining will be attempted, comparing performance with carbide or coated carbide inserts in high-speed machining applications.