Study of cutting force and surface roughness in the turning of polytetrafluoroethylene composites with a polycrystalline diamond tool

Measurement ◽  
2012 ◽  
Vol 45 (6) ◽  
pp. 1367-1379 ◽  
Author(s):  
Catalin Fetecau ◽  
Felicia Stan
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Diamond Tool ◽  
Polycrystalline Diamond

Small Holes Fabrication on Soda Glass by Self-Elastic Polycrystalline Diamond Tool

2012 ◽  
Vol 516 ◽  
pp. 516-521
Author(s):  
Chung Chieh Cheng ◽  
Dong Yea Sheu
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
The Self ◽  
High Quality ◽  
Drilling Tool ◽  
Drilling Tools ◽  
Absorbing Materials ◽  
New Type ◽  
Small Holes

This study describes a novel process to drill small holes in brittle materials such as glass, silicon and ceramic using a self-elastic polycrystalline diamond (PCD) drilling tool. In order to improve the surface roughness and reduce crack of the small holes, a new type of self-elastic PCD drilling tool equipped with vibration absorbing materials inside the housing was developed to fabricate small holes in glass in this study. The self-elastic PCD drilling tools could absorb the mechanical force by the vibration absorbing materials while the PCD tool penetrates into the small holes. Compared to conventional PCD drilling tools, the experimental results show that high-quality small holes drilled in glass can be achieved with cracking as small as 0.02mm on the outlet surface using the self-elastic PCD drilling tool.

A Truing Technique of Flattening Diamond Grains for Fabricating Microstructures with Fine Surfaces

2008 ◽  
Vol 389-390 ◽  
pp. 350-355
Author(s):  
Takeshi Harada ◽  
Takuya Semba
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Diamond Tool ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
Mesh Size ◽  
Diamond Disk ◽  
Working Surface ◽  
Work Material ◽  
Tool Profile

A truing technique that can be used to shape the tip of an electroformed diamond tool into a hemisphere and flatten diamond grains on the tool working surface at the same level as the bond face was developed. A polycrystalline diamond disk whose top surface roughened by electrical discharge machining was partially flattened by grinding was used as a truer. Diamond grains on the tool working surface were successfully flattened along the hemispherical tool profile when the grains mesh size of #1000 was employed. In addition, a grinding test using glasslike carbon as a work material revealed that a surface roughness of less than 50 nm Rz could be obtained in both cases when moving the tool on contour and scanning paths.

Cutting Characteristics of Binderless Diamond Tools in High-Speed Turning of Ti-6Al-4V – Availability of Single-Crystal and Nano-Polycrystalline Diamond –

2016 ◽  
Vol 10 (3) ◽  
pp. 411-419
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
◽  
Akira Hosokawa ◽  
Takashi Ueda ◽  
Tatsuaki Furumoto ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Single Crystal ◽  
Cutting Force ◽  
High Speed ◽  
Diamond Tool ◽  
Cutting Temperature ◽  
Polycrystalline Diamond ◽  
Water Soluble ◽  
Diamond Tools ◽  
Single Crystal Diamond

In this study, the tool performance of two types of binderless diamond tools – single-crystal diamond (SCD) and nano-polycrystalline diamond (NPD) – is investigated in the high-speed cutting of titanium alloy (Ti-6Al-4V) with a water-soluble coolant. The NPD tool allows for a larger cutting force than the SCD tool by dulling of the cutting edge, despite NPD being harder than SCD. This large cutting force and the very low thermal conductivity of NPD yield a high cutting temperature above 500°C, which promotes the adhesion of the workpiece to the tool face, thereby increasing tool wear. Based on the morphology of the tool edge without scratch marks and the elemental analysis by energy-dispersive X-ray spectroscopy (EDX) of both the flank face and the cutting chips, diffusion-dissolution wear is determined to be the dominant mechanism in the diamond tool. A thin TiC layer seems to be formed in the boundary between the diamond tool and the titanium alloy at high temperatures; this is removed by the cutting chips.

Face Turning of Cobalt-Free Tungsten Carbide Using Nano-Polycrystalline Diamond Tool

2016 ◽  
Vol 1136 ◽  
pp. 245-250
Author(s):  
Akinori Yui ◽  
Takayuki Kitajima ◽  
Kenichiro Yoshitomi
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Diamond Tool ◽  
Brittle Materials ◽  
Polycrystalline Diamond ◽  
Zinc Dialkyldithiophosphate ◽  
Micro Cutting ◽  
Fluid Surface ◽  
Hard And Brittle Materials ◽  
Mold Life

The use of hard and brittle materials for manufacturing optical parts, such as dies and molds are required in order to extend mold life. Although, cobalt-free tungsten carbide is one of the hardest materials, micro-cutting is very difficult due to its hardness and its brittleness. This paper investigates face turning of cobalt-free tungsten carbide using a nanopolycrystalline diamond [NPD] tool and Zinc dialkyldithiophosphate (ZnDTP) fluid. Surface roughness of the cobalt-free tungsten carbide achieved was 22nmRz, which is far larger than the theoretical value. That is, traditional cutting theory does not directly apply for face turning of cobalt-free tungsten carbide using NPD tool and ZnDTP fluid.

A Study of the Diamond Tools for Grinding Polycrystalline Diamond

2010 ◽  
Vol 126-128 ◽  
pp. 585-590
Author(s):  
Shenq Yih Luo ◽  
J.K. Ho ◽  
Ming Yi Tsai ◽  
Yi Xian Liu ◽  
William Chen
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
Lower Percentage ◽  
Depth Of Cut ◽  
Workpiece Surface ◽  
Diamond Tools ◽  
Vitrified Bond ◽  
Grinding Efficiency ◽  
Worn Surface

The purpose of this paper was to investigate the grinding performance of two types of cobalt and vitrified bond diamond tools produced by the hot press for the vertical flat grinding polycrystalline diamond. The worn diamond type and the diamond protrusion observed by the toolmaker or SEM after grinding under two different feed rates of 1 and 5 mm/min and the depth of cut of 2 µm with total depth of 10µm were studied. In addition, the grinding efficiency and the workpiece surface roughness produced were analyzed as well. The experiment results showed that when the feed rate of 1 mm/min during the flat grinding PCD was used, a lower percentage of the good diamond, a higher percentage of flat diamond and pulled-out hole on the worn surface of the cobalt bond diamond tool were obtained. For the vitrified bond diamond tool, the good diamond produced showed a higher percentage and flat grit and pulled-out hole displayed a relatively lower percentage. This may be due to the result of the relatively moderate strength and grit retention of the vitrified bond. Furthermore, the diamond protrusion and the grinding efficiency produced for the vitrified bond diamond tool were better than those for the cobalt bond tool. And the PCD surface roughness obtained was better as well.

Finish Cutting of Carbide Mold with Thermally Affected Layer by Diamond Tool

2012 ◽  
Vol 565 ◽  
pp. 382-387
Author(s):  
Kazuki Imazato ◽  
Koichi Okuda ◽  
Hiroo Shizuka ◽  
Masayuki Nunobiki
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Diamond Tool ◽  
Depth Of Cut ◽  
Good Surface ◽  
Finish Cutting ◽  
Ultra Precision ◽  
Cutting Experiments ◽  
Edm Process

This paper deals with finish cutting of thermally affected layer on cemented carbide by a diamond tool in order to machine efficiently the carbide mold with high accuracy and good surface without a polishing. The microstructure of thermally affected layer left by EDM process was observed and analyzed by EPMA. Its hardness and thickness were measured. Subsequently, the cutting experiments were carried out by using a PCD tool and an ultra-precision cutting machine. The effects of the thermally affected layer on the surface roughness, the cutting force and the tool wear were investigated. As a result, it was confirmed that the cutting force decreased with an increase in the depth of cut. Furthermore, it was found that the tool wear and the surface roughness obtained by cutting the thermally affected layer were greater than those of the original workpiece.

scholarly journals Study of cutting force and tool wear during turning of aluminium with WC, PCD and HFCVD coated MCD tools

2020 ◽  
Vol 7 ◽  
pp. 27
Author(s):  
Sisira Kanta Pattnaik ◽  
Minaketan Behera ◽  
Sachidananda Padhi ◽  
Pusparaj Dash ◽  
Saroj Kumar Sarangi
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tools ◽  
Chemical Vapor ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Pcd Tool ◽  
Rolled Aluminum ◽  
Pcd Tools

Enormous developmental work has been made in synthesis of metastable diamond by hot filament chemical vapor deposition (HFCVD) method. In this paper, micro-crystalline diamond (MCD) was deposited on WC–6 wt.% Co cutting tool inserts by HFCVD technique. The MCD coated tool was characterized by the scanning electron microscope (SEM), X-ray diffraction (XRD) and micro Raman spectroscopy (μ-RS). A comparison was made among the MCD tool, uncoated tungsten carbide (WC) tool and polycrystalline diamond (PCD) tool during the dry turning of rolled aluminum. The various major tests were conducted such as surface roughness, cutting force and tool wear, which were taken into consideration to establish a proper comparison among the advanced cutting tools. Surface roughness was measured during machining by Talysurf. The tool wear was studied by SEM after machining. The cutting forces were measured by Kistler 3D-dynamometer during the machining process. The test results indicate that, the CVD coated MCD tool and PCD tool produced almost similar results. But, the price of PCD tools are five times costlier than MCD tools. So, MCD tool would be a better alternative for machining of aluminium.

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