CERAMIC ROUND TOOLS FOR THE MACHINING OF COMPOSITE MATERIALS

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A tool, such as a monolithic ceramic round tool or ceramic inserted round tool fabricated from materials containing silicon nitride, is used for machining composite materials, plastics, and graphite. The tool contains at least a β-silicon nitride phase and a grain boundary phase that is composed of rare earth element oxides such as zirconia, yttria, ceria, and compounds that contain elements such as aluminum, magnesium, silicon, nitrogen and oxygen. The tool is formed by consolidating powder components at elevated temperature. The consolidated ceramic has a porosity of less than 2 vol. %. Composite materials that can be machined include glass fiber-polymer composites, whisker reinforced polymer composites, and carbon fiber containing composites.