Self-lubricating composite, comprises of CuO/ZTA is developed for its application as cutting inserts. The powders of zirconia toughened alumina (ZTA) is prepared through co-precipitation process, further mixed with MgO particles (act as sintering aid) and CuO (provide self-lubrication) using mechanical assistance. After mixing the homogeneous composites are used to fabricate the Inserts obeying powder metallurgy process sintered through Hot isostatic pressing (HIP) and cold press technique. The sintered samples are cut to size using diamond wheel on tool grinder machine. The geometry of inserts are maintained according the international (ISO) standard SNUN 120408. The mechanical characterizations of developed inserts are carried out on mirror polished samples. Crack bridging and crack deflection are the influential phenomenon on the fracture toughness, whereas impurity phases of CuO at grain boundary result in little decrement in hardness. After mechanical characterization the inserts are used to machine AISI 4340 steel on conventional N-26 lathe. Flank wear after 5 min of machining for all inserts are calculated at fixed set of machining parameters to explore the performance of indigenously developed inserts. The self-lubrication phenomenon showed its effect on tool life i.e. thin layer (Patchy layer) formation increases the life of novel inserts.

Keywords: CuO/ ZTA, Self-lubrication, Machining, Flank wear.