Research on diamond turning of large optical metal mirrors. Characteristics of single crystal diamond tools.

This publication focuses on the ultra precision manufacturing of hardened steel parts with single crystal diamond tools for optical applications such as injection moulding. Nowadays optical steel moulds are nickel plated, in order to be able to machine the surface with single crystalline diamond tools. One technology that has proven its potential for replacing this procedure is the ultrasonic assisted diamond turning technique. This process allows direct machining of hardened steel with single crystal diamond tools, which is conventionally not possible due to the high tool wear. The ultrasonic assisted diamond turning process is applied in order to machine different steel alloys that are conventionally used for mould manufacturing in injection moulding. The goal is to analyze the influence of the steel alloy and the material microstructure on the machining results. The presented analysis show the capabilities of this new technology and opens the door for it to compete with established manufacturing processes, such as the manufacturing of nickel plated mold inserts.

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Performance of single crystal diamond tools with different rake angles during micro-grooving on electroless nickel plated die materials

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-006-0535-1 ◽

2006 ◽

Vol 33 (9-10) ◽

pp. 891-899 ◽

Cited By ~ 22

Author(s):

A. Q. Biddut ◽

M. Rahman ◽

K. S. Neo ◽

K. M. Rezaur Rahman ◽

M. Sawa ◽

...

Keyword(s):

Single Crystal ◽

Electroless Nickel ◽

Diamond Tools ◽

Single Crystal Diamond ◽

Die Materials ◽

Micro Grooving

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Nanometric ductile cutting characteristics of silicon wafer using single crystal diamond tools

Journal of Vacuum Science & Technology B Microelectronics and Nanometer Structures Processing Measurement and Phenomena ◽

10.1116/1.3071855 ◽

2009 ◽

Vol 27 (3) ◽

pp. 1361 ◽

Cited By ~ 16

Author(s):

Kui Liu ◽

Dunwen Zuo ◽

X. P. Li ◽

M. Rahman

Keyword(s):

Single Crystal ◽

Silicon Wafer ◽

Diamond Tools ◽

Ductile Cutting ◽

Single Crystal Diamond

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E01 Analysis of machining errors in high speed shaping with single crystal diamond tools

The Proceedings of The Manufacturing & Machine Tool Conference ◽

10.1299/jsmemmt.2010.8.267 ◽

2010 ◽

Vol 2010.8 (0) ◽

pp. 267-268

Author(s):

Sho NAKADE ◽

Daisuke KONO ◽

Atsushi MATSUBARA

Keyword(s):

Single Crystal ◽

High Speed ◽

Diamond Tools ◽

Machining Errors ◽

Single Crystal Diamond

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

International Journal of Automation Technology ◽

10.20965/ijat.2016.p0411 ◽

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.

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Single-crystal diamond tools formed using a focused ion beam: Tool life enhancement via heat treatment

Diamond and Related Materials ◽

10.1016/j.diamond.2014.07.013 ◽

2014 ◽

Vol 49 ◽

pp. 14-18 ◽

Cited By ~ 16

Author(s):

Noritaka Kawasegi ◽

Kazuma Ozaki ◽

Noboru Morita ◽

Kazuhito Nishimura ◽

Hideki Sasaoka

Keyword(s):

Heat Treatment ◽

Single Crystal ◽

Tool Life ◽

Focused Ion Beam ◽

Ion Beam ◽

Diamond Tools ◽

Single Crystal Diamond ◽

Life Enhancement

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Experimental Investigation on Precision Cutting Ti6Al4V Alloy Using Single Crystal Diamond Tools

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.633-634.832 ◽

2014 ◽

Vol 633-634 ◽

pp. 832-835

Author(s):

Lin Hua Hu ◽

Ming Zhou

Keyword(s):

Surface Roughness ◽

Single Crystal ◽

Cutting Speed ◽

Cutting Parameters ◽

Limited Range ◽

Machined Surface ◽

Diamond Tools ◽

Single Crystal Diamond ◽

Machined Surface Roughness ◽

Titanium Alloy Ti6al4v

In this work, cutting experiments were carried out on titanium alloy Ti6Al4V by using single crystal diamond tools to investigate the effects of cutting parameters on machined surface roughness. Experimental results show machined surface roughness decreases with increases in the cutting speed within a limited range, begins to increase as the factors reaches to certain values respectively, and decreases with increases in feed rate. Cutting depth has no significant influence on the machined surface roughness. The results also show that dominant mechanisms of the single crystal diamond tools are abrasive wear and adhesion wear.

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