Ceramic cuttingtools are made of

The raw materials, powder and water, are mixed and pulverised by a ball mill (grinder). The process of creating a homogeneous fine-grain material makes the later firing process easier. This stage is important for making hard and strong ceramic tools.

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Carbon fiber is the darling material of engineers that want to produce things both strong and light. But it comes with a serious downside: It has many environmental issues. Carbon fiber requires 17 times as much energy to produce as steel, and, more problematic, is not easily recycled. The world produces more than 85,000 metric tons of carbon fiber per year, and at end of life most of that material ends up in a landfill or incinerated.

Carbon-fiber-reinforced polymer composites are difficult to recycle for the same reason that they’re strong. Long, carefully aligned carbon fibers are fixed in a polymer matrix and cured at a high temperature. “Once cured, due to the mixed nature of the composition, CFRP composite cannot simply be melted down and reformed,” said Ali Hadigheh, a professor in the School of Civil Engineering at the university. Carbon fibers are difficult to recycle and the global demand is great. There are a few methods of recycling carbon fiber, but they result in a seriously degraded material. The most common techniques are to shred, crush, or mill the substance, but those methods produce a mix of powdered and fibrous material that simply does not perform as well as virgin carbon fiber, said Hadigheh. “Current recycling methods are inept, as they cause major reduction in mechanical and physical properties of recovered fiber,” he said. More for You: Catalyzing a Solution for Plastic Waste Hadigheh developed a method that promises to change that problem. It is a two-part process, pyrolysis followed by oxidation. During pyrolysis, CFRP is heated in the absence of oxygen and is broken down. But this stage leaves a char on the fiber which would prevent a good bond in a resin matrix. The second stage, oxidation at a high temperature, removes this char.

Demand for carbon fiber has been growing by 10 percent a year for some time. Hadigheh’s cheap efficient method for recycling could keep carbon from becoming another resource that does more harm to the planet than good.

“Pyrolysis and oxidation alone are not enough to preserve carbon fibers and these processes have existed for some time already,” he said. “To ensure a high quality recovery and economic efficiency, thermal decomposition of CFRPs need to be guided by analysing the energy required to initiate a chemical reaction in the composit, and separate carbon fibres from the surrounding resin matrix. Editor’s Pick: How Robots Are Helping Us to Recycle Better "What makes our method so successful is that we have added specific parameters such as temperature, heating rate, atmosphere or time spent being oxidised and heated that preserve the functionality of carbon fiber.”

CVD coating is also used for cemented carbide tools, but the coating components and formulations are customised specifically for ceramic tools.

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Chamfer (drilling). Use the Chamfer page to create a chamfer without having to define the hole as a tapered hole. Note: This page is available only if you ...

The tools come sharp and ready to use. To keep them sharp I've created a simple sharpening guide to duplicate the way I grind each tool. Let it be known I have ...

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Now, researchers at the University of Sydney have created a method for recycling carbon fiber that makes it nearly as good as new.

Feed rates also affect the tool life and power consumption during machining, but their effects are usually negligible compared to cutting force. Instead, feed ...

Hot air is blown onto the material mixture from stage ① which causes the fine grains to coalesce into larger round forms. This makes it easier to press the mixture in a later process and create ceramic inserts in various shapes.

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By heating the pressed shapes, (aggregates of ceramic powders) the ceramic particles adhere to each other reducing the gaps and thereby solidifying and hardening the insert. To make ceramic tools that can withstand high-speed machining, it is essential to manage sintering temperature and time more finely than cemented carbide tools. This process produces hard, strong ceramic tools and also changes the colour of the material due to a chemical reaction between the insert components.

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“Our optimized two-phase process enables us to produce clear recyclate fibrer with excellent surface characteristics as well as high mechanical strength,” said Hadigheh. This results in a carbon fiber that is ready for adhesion and reuse.

Recycled carbon fiber will likely cost 70 percent of the price of virgin carbon fiber. Compared to the production of new carbon fiber, the new recycling process will reduce emissions by 90 percent to 95 percent and will use 98 percent less energy. “Substituting virgin carbon fiber with recycled carbon fiber would save enough energy to power 175,000 homes in a year,” said Hadigheh.

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“With current production growth, CFRP materials will be one of the largest waste streams around the world in the next decade,” he said. “If sustainable methods are not developed to reuse and recycle composite waste, the potential hazards of these materials to the environment, human health, and economy, will be far greater than the projected hazards of plastic waste.”

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Powder is packed into a mold to which high pressure is applied to form inserts. A pressing force of 1 – 2 tons/cm2 is applied in order to solidify the ceramic powder. To put it into perspective, this would be equivalent to a hippopotamus stepping on the insert mold. Ceramics have a lighter specific gravity compared to cemented carbides. So, using the carbide pressing process would result in cracks and distortions of the ceramic after sintering. Therefore, the pressing process is exclusive to ceramic tools. The insert pressing process compacts the ceramic material, but there are still gaps between the particles and the inserts are fragile. The process then moves to the firing stage.

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He noted the strength of the fibers does slightly degrade after going through the process. It’s not enough to outweigh the environmental and cost benefits of recycling, but it could become an issue if the fibers are recycled a second or third time. Hadigheh is currently investigating ways of retaining the mechanical and surface properties of carbon fiber after repeated recyclings. He’s also developed, and filed for a patent, of a new technique for realigning short fibers. Reader’s Choice: Recycling Desalination Waste “This is a vital stage since without precise fiber alignment, it is not possible to reuse recycled fibers for high-grade structural components,” he said.