Milling of alumina-based ceramic foams: tool material effects

Abstract. Porous ceramics are recognized to have the potential be used for a wide variety of industrial applications, such as catalyst support and molten metal filter. It is common practice adjust shape in pre-sintering stage order obtain various configurations but some limitations due premature failure product, marked tool wear or inhomogeneous shrinkage during processing stages may arise, whenever complex requested. Almost same happens case post-sintering machining leading, most cases, an inefficient process characterized by severe poor final product quality. Such problems, related material, material removal modes hence parameters represent huge limitation many applications above materials. Milling alumina-based ceramic foams sintered state focus present work. An experimental campaign has been carried out at fixed axial depth cut, feed rate, number passes, spindle speed under flood lubrication regime varying (aluminum oxide-based, diamond-coated). Tool mechanisms quality investigated through surface analysis verify workability alumina based wear.