Detection of orientation-dependent, single-crystal diamond tool edge wear using cutting force sensors, while spin-turning silicon

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.

Download Full-text

Effect of Cutting Fluid on Diamond Tool Life under Micro V-Groove Turning of Cobalt-Free Tungsten Carbide

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1017.181 ◽

2014 ◽

Vol 1017 ◽

pp. 181-186 ◽

Cited By ~ 3

Author(s):

Akinori Yui ◽

Takayuki Kitajima ◽

Peter Krajnik ◽

Katsuko Harano ◽

Hitoshi Sumiya ◽

...

Keyword(s):

Wear Resistance ◽

Tungsten Carbide ◽

Tool Life ◽

Vegetable Oil ◽

Diamond Tool ◽

Rake Angle ◽

Cutting Fluid ◽

Tool Edge ◽

Tool Edge Wear ◽

Edge Wear

Micro-machining of hard dies and molds for optical parts or precision instruments is required to extend die and mold life. This paper investigates the effect of cutting fluid on diamond tool life under micro V-groove turning of cobalt-free tungsten carbide. Zinc dialkyldithiophosphate fluid (ZnDTP) displayed excellent diamond tool wear resistance in previous experiments. The performance of this cutting fluid is compared to newly developed vegetable oil based cutting fluid with dispersed MoS2 nanotubes. This paper investigates nanopolycrystalline diamond (NPD) tool life with a rake angle of 0° and-30° under continuous micro V-groove turning (i.e. face turning), of cobalt-free tungsten carbide using the developed cutting fluids. Superior diamond tool edge wear resistance is observed when using the dispersed MoS2 nanotubes in vegetable oil and using a NPD tool with a-30° rake angle.

Download Full-text

Microgrooving on electroless nickel plated materials using a single crystal diamond tool

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-004-2273-6 ◽

2005 ◽

Vol 27 (9-10) ◽

pp. 911-917 ◽

Cited By ~ 14

Author(s):

K.M. Rezaur Rahman ◽

M. Rahman ◽

K.S. Neo ◽

M. Sawa ◽

Y. Maeda

Keyword(s):

Single Crystal ◽

Diamond Tool ◽

Electroless Nickel ◽

Single Crystal Diamond ◽

Single Crystal Diamond Tool

Download Full-text

The Condition Monitoring of the Micro V-Grooving with a Single Crystal Diamond Tool Using the AE Technology

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.1107 ◽

2011 ◽

Vol 264-265 ◽

pp. 1107-1117 ◽

Cited By ~ 1

Author(s):

Su Hoon Jang ◽

Hae Woong Kwon ◽

Ik Soo Kang ◽

Jeong Suk Kim ◽

Myung Chang Kang

Keyword(s):

Single Crystal ◽

Diamond Tool ◽

Machined Surface ◽

Machining Conditions ◽

Single Crystal Diamond ◽

Single Crystal Diamond Tool ◽

Micro Grooving ◽

Ae Signal ◽

Surface Profiles ◽

Ae Signals

This study deals with the micro v-grooving of a single crystal diamond tool that is implemented on a 3-axis micro-stage. A method for monitoring the machining conditions is investigated using acoustic emission (AE) signals and cutting force signals in the micro-grooving. The AE signals and machined surface profiles are obtained under various machining conditions. The signals are acquired from an AE sensor that is attached to the tool holder and are investigated to identify the correlation with the machined surface profiles. It is found that the AE signal is an effective parameter for monitoring the texture of the machined surface.

Download Full-text