Article

A novel zirconia toughened alumina (ZTA) composite was synthesized for cutting inserts used in machining Aluminum alloy 5052. The inserts, produced via powder metallurgy in line with ISO SNUN 120,408, demonstrated superior performance compared to conventional tools.

Key machining mechanisms affecting cutting force, surface roughness, noise, and vibration signals were identified. Noise signals were shown to effectively monitor cutting performance, with depth of cut being the most significant factor. Optimal cutting conditions were found at a speed of 750 rpm, feed rate of 0.16 mm/rev, and depth of cut of 1 mm.