Method of using a ceramic cutting tool with chip control

A method for the high speed machining of metallic materials, comprising the steps of:

• machining said metallic material at a speed of about 500 to 5,000 sfm and a feed of about 0.002 to 0.02 ipr, with a cutting edge of an indexable ceramic cutting insert comprising:
• a cutting edge,
• a flank face, and
• a rake surface with an integral as molded means for chip control thereon;
• and wherein said cutting edge is formed at the juncture of said flank face and said rake face;
• wherein a depth of cut is as great as the length of a cutting insert side;
• and wherein chips formed from said metallic material during said machining communicate with at least a portion of said integral as molded means for chip control and thereby obtain a desired and controllable configuration.

A method for the high speed machining of metallic materials, comprising the steps of:

• machining said metallic material at a speed of about 500 to 5,000 sfm, a feed of about 0.002 to 0.02 ipr, and a depth of cut of about 0.015 to 0.5 inch, with a cutting edge of an indexable ceramic cutting insert comprising:
• a top rake face,
• a bottom rake face,
• a flank face joining said top rake face and said bottom rake face,
• a first cutting edge formed at the juncture of said top rake face and said flank face,
• a second cutting edge formed at the juncture of said bottom rake face and said flank face,
• a first as molded chip control groove in said top rake face, and
• a second as molded chip control groove in said bottom rake face;
• wherein said ceramic has a fracture toughness of at least about 4 MPam.sup.1/2 and wherein chips formed from said metallic material during said machining communicate with at least a portion of at least one of said as molded chip control grooves and thereby obtain a desired and controllable configuration.

A method for the high speed machining of metallic materials, comprising the steps of:

• machining said metallic material at a speed of about 500 to 5,000 sfm, a feed of about 0.002 to 0.02 ipr, and a depth of cut of about 0.015 to 0.5 inch, with a cutting edge of a indexable ceramic cutting insert comprising:
• a first cutting edge extending in a first direction;
• a second cutting edge extending in a second direction and joined to said first cutting edge at a corner of the insert;
• a rake face with an integral means for controlling chip formation extending along said first cutting edge, said second cutting edge and said corner of said insert;
• wherein said first cutting edge and said second cutting edge define a plane;
• a surface of said means for controlling chip formation extending below said plane, and said surface is in an as-molded condition;
• and wherein said indexable ceramic cutting insert is composed of a ceramic composition of an alumina based ceramic and wherein chips formed from said metallic material during said machining communicate with at least a portion of said as molded means for chip control and thereby obtain a desired and controllable configuration.