scholarly journals The Performance of Polycrystalline Diamond (PCD) Tools Machined by Abrasive Grinding and Electrical Discharge Grinding (EDG) in High-Speed Turning

2021 ◽  
Vol 5 (2) ◽  
pp. 34
Author(s):  
Guangxian Li ◽  
Ge Wu ◽  
Wencheng Pan ◽  
Rizwan Abdul Rahman Rashid ◽  
Suresh Palanisamy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Flank Wear ◽  
Polycrystalline Diamond ◽  
Machining Efficiency ◽  
Crater Wear ◽  
Wear Process ◽  
High Speed Turning ◽  
Tools Wear ◽  
Pcd Tools

Polycrystalline diamond (PCD) tools are widely used in industry due to their outstanding physical properties. However, the ultra-high hardness of PCD significantly limits the machining efficiency of conventional abrasive grinding processes, which are utilized to manufacture PCD tools. In contrast, electrical discharge grinding (EDG) has significantly higher machining efficiency because of its unique material removal mechanism. In this study, the quality and performance of PCD tools machined by abrasive grinding and EDG were investigated. The performance of cutting tools consisted of different PCD materials was tested by high-speed turning of titanium alloy Ti6Al4V. Flank wear and crater wear were investigated by analyzing the worn profile, micro morphology, chemical decomposition, and cutting forces. The results showed that an adhesive-abrasive process dominated the processes of flank wear and crater wear. Tool material loss in the wear process was caused by the development of thermal cracks. The development of PCD tools’ wear made of small-sized diamond grains was a steady adhesion-abrasion process without any catastrophic damage. In contrast, a large-scale fracture happened in the wear process of PCD tools made of large-sized diamond grains. Adhesive wear was more severe on the PCD tools machined by EDG.

Experimental Study on Performance of CBN-Coated, CBN-Uncoated and PCD Tools in Turning Al 2124 SiC (45%wt) PMMC

2013 ◽  
Vol 567 ◽  
pp. 27-31 ◽  
Author(s):  
Muguthu Joseph Njuguna ◽  
D. Gao
Keyword(s):  
Experimental Study ◽  
Tool Wear ◽  
Metal Matrix ◽  
Flank Wear ◽  
Tool Material ◽  
Crater Wear ◽  
Pcd Tool ◽  
Particulate Metal ◽  
Tools Wear ◽  
Pcd Tools

The machining of PMMCs is very difficult due to the highly abrasive and intermittent nature of the reinforcement. It is therefore necessary to choose tool material wisely. The focus of this paper was to assess performance of CBN-uncoated, CBN-coated and PCD tools with respect to tool wear, wear mechanism and cutting force while turning of Al 2124 SiC (45%wt) Particulate Metal Matrix Composite. Experimental results reveal that abrasion and chipping presented the most prevalent mode of wear among the CBN-uncoated, CBN-coated and PCD tools. Flank and crater wear were observed in all tools with flank wear being more prevalent in CBN-coated and CBN-uncoated tools. Wear among PCD tool was low as compared to CBN-uncoated CBN-coated. PCD tool is more suitable for cutting Al 2124 SiC(45%wt) PMMC.

Performance of Cutting Tools in High Speed Milling of SiCp/Al Composites

2012 ◽  
Vol 591-593 ◽  
pp. 311-314 ◽  
Author(s):  
Yang Jun Wang ◽  
Ming Qiang Pan ◽  
Tao Chen ◽  
Ji Zhu Liu ◽  
Li Guo Chen
Keyword(s):  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Chemical Vapor ◽  
Polycrystalline Diamond ◽  
Cvd Diamond ◽  
Optical Microscope ◽  
Coated Tools ◽  
Tools Wear ◽  
Pcd Tools

This paper presents an experimental study in milling of SiCp/Al composites on a high precision machine by using chemical vapor deposition(CVD) diamond coated tools and polycrystalline diamond (PCD) tools. The tool wear was observed and measured by an optical microscope and a scanning electron microscope (SEM). The results show that the coating rupture causes the failure of the CVD diamond coated tools. The PCD tools’ wear is less. At the relatively low cutting speed, the wear pattern of PCD tools is the flank wear which caused by the abrasion of SiC particles. Due to the low cutting temperature, the graphitization of PCD tools does not happen. The wear mechanism of PCD tools will be the abrasive and adhesive wear.

An Analysis of the Wear of Tungsten Carbide and Polycrystalline Diamond Inserts Turning Ti-6Al-4V

2011 ◽  
Author(s):  
David Schrock ◽  
Xin Wang ◽  
Patrick Kwon
Keyword(s):  
Thermal Conductivity ◽  
Grain Size ◽  
Tool Wear ◽  
Flank Wear ◽  
Polycrystalline Diamond ◽  
Laser Scanning Microscopy ◽  
Rake Face ◽  
Crater Wear ◽  
Pcd Tools ◽  
Face Temperature

Dry turning experiments on Ti-6Al-4V were conducted using two grades (finer and coarser) of carbides and polycrystalline diamond (PCD) inserts to study tool wear. Despite of minor compositional difference between two carbide grades, both grades contain 6% Co. Crater wear and flank wear were measured using Confocal Laser Scanning Microscopy (CLSM). Three dimensional rake surface topographies were reconstructed from the CLSM data and wear profiles were extracted. Finite Element Analysis (FEA) was conducted to study the effects of cutting conditions and thermal properties on rake face temperature. Flank wear on the carbide tools indicated that the inserts with the finer grain size exhibited smaller flank wear than the insert of the coarser grain size. This was attributed to reduced abrasive wear in the finer grained inserts as a result of a higher hardness. The carbide grade with a coarser grain size had an enhanced ability to resist crater wear, likely from lower rake face temperatures and the differences in the compositions. It is known that coarser grain carbides have a higher thermal conductivity resulting from increased grain contiguity. FEA was used to study the temperature difference between the two grain-sizes and the effect of thermal conductivity on temperature gradients. Tool wear of the PCD inserts was also studied. The PCD tools showed significant adhesive wear at the 200sfm cutting speed, transitioning to crater wear at 400sfm. With a high thermal conductivity, it is possible that rake face temperatures were low enough to alter the wear mechanism. FEA supports this hypothesis, as the maximum rake face temperature for the PCD inserts were only around 900°C at 200sfm.

Electrical Discharge Grinding (EDG) of Polycrystalline Diamond - Effect of Machining Polarity

2014 ◽  
Vol 1025-1026 ◽  
pp. 628-632 ◽  
Author(s):  
Mohammad Zulafif Rahim ◽  
Song Lin Ding ◽  
John Mo
Keyword(s):  
Electrical Discharge ◽  
Complex Geometry ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Morphological Examination ◽  
Carbon Structure ◽  
Finishing Process ◽  
Advanced Machining ◽  
The Difference ◽  
Pcd Tools

Electrical discharge grinding (EDG) is an advanced machining process and can be utilised to fabricate complex geometry of PCD tools. However, the PCD removal mechanism in this process is complicated. This study was carried out to understand the difference in PCD surface structure with difference EDG polarities. The study revealed that the finishing process with negative polarity is the reason for the porous structure on the surface. Further analysis on the chemical element and carbon structure were implemented as the morphological examination of the surface.

Experimental Study of Tool Wear during Quasi High Speed Turning Titanium Alloy with Large Cutting Depth

2014 ◽  
Vol 800-801 ◽  
pp. 548-552
Author(s):  
Li Fu Xu ◽  
Wei Liang Dong ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Data ◽  
Titanium Alloy ◽  
High Speed ◽  
Flank Wear ◽  
Rake Face ◽  
Cutting Depth ◽  
Tool Flank Wear ◽  
High Speed Turning ◽  
Flank Face ◽  
Cutting Speeds

The wear morphology of rake face and flank face of tool is investigated by turning titanium alloy TC4 with CBN solid tool. It has been observed that the main wear form of rake face and flank face of tool is groove wear. The relation between tool flank wear and cutting speeds, feed rate, and cutting depth obtained from experimental data is given.

Sustainable High Speed Dry Cutting of Magnesium Alloys

2012 ◽  
Vol 723 ◽  
pp. 3-13
Author(s):  
Yue Bin Guo ◽  
Zhan Qiang Liu
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Energy Use ◽  
Internal State ◽  
Polycrystalline Diamond ◽  
Mg Alloys ◽  
Plasticity Model ◽  
Machining Performance ◽  
Dry Cutting ◽  
Pcd Tools

Magnesium (Mg) components can significantly reduce energy use due to their low densities compared to the majority alloys. Mg alloys are often machined to fit individual cases. However, process mechanics by high-speed dry cutting of Mg alloys are poorly understood. This study focuses on machining ability of biomedical magnesium-calcium (Mg-Ca) alloys. First, it presents a modeling approach of mechanical behavior of Mg-Ca0.8 (wt %) alloy under cutting regimes using the internal state variable (ISV) plasticity model. Then, the ISV plasticity model is implemented to simulate high speed dry cutting of Mg-Ca0.8 alloy by finite element method. Last, machining performance in the context of sustainability is discussed. Excellent surface finish can be achieved in the range of high cutting speeds. Continuous chip formation predicted by the finite element simulation is verified by high speed dry cutting of Mg-Ca0.8 using polycrystalline diamond (PCD) inserts. Chip ignition as the most hazardous aspect in machining Mg alloys does not occur for in high-speed dry cutting with sharp PCD tools. The predicted temperature distribution well explains the reason for the absence of chip ignition in high speed dry cutting of Mg-Ca0.8 alloy. A mechanism of built-up layer (BUL) formation is proposed.

Wear Characteristics of Binder-Less Nano-Polycrystalline Diamond and Cubic Boron Nitride

2014 ◽  
Vol 1017 ◽  
pp. 406-410 ◽  
Author(s):  
Hitoshi Sumiya ◽  
Katsuko Harano
Keyword(s):  
Boron Nitride ◽  
Chemical Reaction ◽  
High Speed ◽  
Single Phase ◽  
Cubic Boron Nitride ◽  
Polycrystalline Diamond ◽  
Wear Characteristics ◽  
Wear Process ◽  
Wear Rates ◽  
Starting Condition

Wear characteristics of binder-less (single-phase) nanopolycrystalline diamond (NPD) and cubic boron nitride (BL-PcBN) were investigated by rubbing them against various ceramics such as SiO2, Si3N4, Al2O3 and SiC. The wear rates of NPD and BL-PcBN against SiO2 and Si3N4 at high speed rubbing (280-360 m/min) at a loading pressure of 55 MPa (starting condition) were considerably high, indicating the main wear process is a chemical reaction. BL-PcBN specimens were found to be worn at much higher (more than ten times) rates than NPD, suggesting that cBN highly reacts with these ceramics in comparison with diamond under the experiment condition.

scholarly journals Selection of Machining Parameters Using a Correlative Study of Cutting Tool Wear in High-Speed Turning of AISI 1045 Steel

2018 ◽  
Vol 2 (4) ◽  
pp. 66 ◽  
Author(s):  
Luis Hernández González ◽  
Yassmin Seid Ahmed ◽  
Roberto Pérez Rodríguez ◽  
Patricia Zambrano Robledo ◽  
Martha Guerrero Mata
Keyword(s):  
High Speed ◽  
Manufacturing Industry ◽  
Cutting Tool ◽  
Flank Wear ◽  
Machining Parameters ◽  
High Speed Turning ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The manufacturing industry aims to produce many high quality products efficiently at low cost, thereby motivating companies to use advanced manufacturing technologies. The use of high-speed machining is increasingly widespread; however, it lacks a deep-rooted knowledge base needed to facilitate implementation. In this paper, response surface methodology (RSM) has been applied to determine the optimum cutting conditions leading to minimum flank wear in high-speed dry turning on AISI 1045 steel. The mathematical models in terms of machining parameters were developed for flank wear prediction using RSM on the basis of experimental results. The high speed turning experiments were carried out with two coated carbide and a cermet inserts using AISI 1045 steel as work material at different cutting speeds and machining times. The models selected for optimization were validated through the Pareto principle. Results showed the GC4215 insert to be the most optimal option, because it did not reach the cutting tool life limit and could be used for the whole range of cutting parameters selected. To quantitatively evaluate the usefulness of the cutting tools, it was proposed the coefficient of use of the tools from the results of the contour graphs. The GC4215 insert showed 100% effectiveness, followed by the GC4225 with 98.4%, and finally, the CT5015 insert with 83%.

Machining of Graphite/Epoxy Composite Materials With Polycrystalline Diamond (PCD) Tools

1991 ◽  
Vol 113 (4) ◽  
pp. 430-436 ◽  
Author(s):  
M. Ramulu ◽  
M. Faridnia ◽  
J. L. Garbini ◽  
J. E. Jorgensen
Keyword(s):  
Flank Wear ◽  
Epoxy Composite ◽  
Wear Behavior ◽  
Polycrystalline Diamond ◽  
Surface Characteristics ◽  
Machining Time ◽  
Machined Surface ◽  
Surface Textures ◽  
Small Cracks ◽  
Pcd Tools

Machining of graphite/epoxy composite material is investigated by turning (cutoff) tests using different grades of polycrystalline diamond (PCD) inserts. The wear behavior of the PCD cutting edge is characterized by small cracks, rounded edges, and flank wear. The flank wear growth rate was found to depend on the microstructure of the tool and machining time. The coarser the PCD grade was, the better the wear resistance. The machined surface characteristics were evaluated by analyzing the surface roughness data and by scanning electron microscopy inspection of machined surface textures. Surface quality was found to get better with the cutting time.

Surface integrity under diamond tool wear effects in ultra-precision raster milling of a Zn–Al–Cu alloy

2018 ◽  
Vol 233 (4) ◽  
pp. 1111-1118 ◽  
Author(s):  
Zengwen Dong ◽  
Shaojian Zhang ◽  
Zhiwen Xiong
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
High Speed ◽  
Diamond Tool ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Phase Changes ◽  
Crater Wear ◽  
Cu Alloy ◽  
Ultra Precision

In ultra-precision raster milling, the material removal process determines surface integrity. In this study, surface integrity was discussed under diamond tool wear effects in ultra-precision raster milling of a Zn–Al–Cu alloy. The results firstly showed that under high speed cutting in ultra-precision raster milling, quenching took place with phase decomposition (namely twin phase changes) with a deformation thickness of even less than 100 nm. Flank wear enhanced phase changes, promoted surface hardening, degraded surface quality, and increased deformation thickness, but crater wear gave better surface integrity. The intrinsic reason is that flank wear caused more external stress but crater wear was reverse, well supported by finite element simulation in orthogonal cutting. Significantly, it provides a further insight into diamond tool wear effects on surface integrity in ultra-precision raster milling of a Zn–Al–Cu alloy.

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