Ceramika

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The Institute of Metal Cutting 30-011 Kraków, ul.
Wroclawska 37A tel. [phone], fax. 4812
63-39-490 email ios_at_ios.krakow.pl

• The Institute of Metal Cutting (IOS), established
  in Kraków in 1949, is a research center
  specialized in problems of technology and
  techniques of
• metal cutting,
• abrasive machining,
• unconventional methods of machining,
• technical metrology,
• automation of manufacturing and assembly
  processes.

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• The IOS activity is carried on in following
  areas
• scientific research,
• development works (non-routine design jobs -
  constructional and concerning process engineering
  - requiring a scientific substructure) and
  implementation works,
• production of unique apparatus and single machine
  tools or small special batches of them, as well
  as technological devices, tools and tooling
  likewise measuring and testing systems -
  characterized by innovative solutions,
• service in scientific and technological area,
• certification of products and investigations for
  its needs,
• harmonization of Polish technical regulations
  according to the regulations obligatory in
  European Union,
• consultations, experts' appraisements and
  reports, training, scientific and technical
  information.

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• Research and development (R D) works concern
  the following main objects
• metal cutting and grinding technology,
  development of tools and tooling, special
  machine tools,
• engineering of cutting materials and wear
  resistant coatings,
• unconventional methods for machine parts
  generation, especially electrodischarge and
  electrochemical machining,
• technical metrology concerning particularly
  geometrical quantities,
• automation of assembly and inspection
  operations,
• development of special software for cutting
  operations, abrasive and EDM machining,
• methods for testing functional quality of
  machine tools, tools, technological equipment
  and cutting fluids.

Product investigations are conducted in
accredited Research Laboratory consisting of 9
specialized sections.
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Research Projects carried in contribution of IOS

• Research on clean hybrid micromachining (HMM)
  processes - INCO- COPERNICUS, Concerted Action
  Contract IC15-CT98-0801 (1997-2001),
  co-ordination IOS
• Towards ecologically friendly machining (ECOFRIM)
  - INCO-COPERNICUS, Concerted Action Contract
  IC15-CT98-0810 (1998-2001), co-ordination
  University of Bradford (The United Kingdom)
• Abrasive water jet cutting, a clean technology -
  INCO-COPERNICUS, Concerted Action Contract
  IC15-CT98-0821 (1998-2001) co-ordination
  Universität Hannover (Germany)
• ELESIN Electrochemical-erosion sinking process
  for high precision holeproduction - CRAFT, 5. PR
  Growth nr CRAF-1999-71005 (2002-2004),Advance
  d Cutting Machinery, co-ordination The United
  Kingdom
• NAS-SPECTRUM Super Precision Electro-Chemical
  Machining Technology including Recycling of
  Usable Materials 5. PR Growth GRD3-2001-60066
  (2002-2004), co-ordination Philips (Holland)

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Materials Engineering Departments activity in
IOS

• The Materials Engineering Department of the
  Institute of Metal Cutting (IOS) is engaged in R
  D works for the needs of industry, involved in
  problems of
• manufacturing technology
• sintered tool materials for metal cutting
• designing and production tools in small batches
  for industrial plants
• The research activity of the Materials
  Engineering Department has been oriented towards
  working out the IOSs own technology to produce
  the sintered cutting tool materials on the basis
  of
• alumina
• superhard polycrystalline diamond (PCD)
• cubic boron nitride (PcBN)

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GRADES AND APPLICATIONS Ceramic inserts
distinguished by high wear resistance are used
for machining a wide range of materials such as
normalized steels, hardened steels, cast iron and
special alloys. They enable an efficient
machining of materials that a little time ago
could be worked only by grinding.Indexable
inserts TA-Z type based on AI2O3 ZrO2 are
designed for straight turning operations and for
surface milling (steels and grey cast iron).
Inserts TA based on pure AI2O3 are recommended
first of all for turning cast iron and steel in
normalized state and hardened up to 300 HB.
Indexable inserts TW (AI2O3 TiC) and TW-N
(AI2O3 TiC TiN) are designed for the
finishing and moderately accurate machining of
cast iron and toughened steels (up to hardness of
58 HRC).
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• ADVANTAGES AND EFFECTS OF USING CERAMIC INSERTS
• To main advantages of application in IOS
  manufactured ceramic inserts belong
• possibility of high duty working (with high
  machining rates),
• obtaining of surfaces having very low roughness
  (in many cases grinding is superfluous),
• possibility of turning tempered materials with
  hardness up to 58 HRC,
• possibility of ecological "dry cutting" - without
  application of cutting fluids,

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• It represents the complete processing route for
  producing technical ceramics with particular
  regard to cutting ceramics starting from
• initial powders
• shape forming
• sintering, finishing technologies up to trade
  product
• Testing of mechanical properties
• fracture toughness
• subcritical crack growth
• crack growth resistance (R-curve)
• indentation fracture toughness
• flexural strength
• indirect splitting strength
• microhardness

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(RTD) facilities
Shaping techniques (dry pressing, cold isostatic
pressing) Sintering (furnaces firm of Gero
Hochtemperaturöfen GmbH with different
atmosphere argon, nitrogen, vacuum, vacuum
Balzers, electrical high temperature Naberthern,
HPS Bridgman type apparatus with pressure 9 GPa,
tem. 2073K. Finishing and characterisation
URD6 X-ray diffractometer, Instron Testing
Instrument , SEM with X-ray microanalyzer,
microhardness series FM7
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PROPOSAL OF RESEARCH WORKS
The subject matter of future work has been
proposed. in view of pro-ecological and
economical aspect of manufactured tool ceramics
towards limitation of using lubricants in metal
cutting and improvement of fracture
toughness Advanced nanoceramics with particular
regard to alumina-(doped Y,Ce) zirconia
nanocomposites for highly efficient machining.
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