Wear Mechanism of Diamond Tool against Mold Steel in Single Point Diamond by Molecular Dynamics

2016 ◽  
Vol 851 ◽  
pp. 186-190 ◽  
Author(s):  
Fei Xie ◽  
Zhu Ji Jin ◽  
Xiao Guang Guo ◽  
Shuang Ji Shi
Keyword(s):  
Molecular Dynamics ◽  
Wear Mechanism ◽  
Md Simulation ◽  
Diamond Tool ◽  
Single Point ◽  
Diamond Turning ◽  
Precision Manufacturing ◽  
Atomic Position ◽  
Ultra Precision ◽  
Rapid Tool

Owing to the extremely rapid tool wear, ultra-precision manufacturing of mold steel through single point diamond turning (SPDT) operation becomes a challenging task. Molecular dynamics (MD) simulation is an appropriate tool to study nanoscale processes occurring at the femtosecond/picosecond timescale. The wear mechanism of the diamond tool is discussed by means of molecular dynamics in which atomic position variation, temperature fluctuations were involved. According to the analysis results, iron atoms have unpaired d electrons, these iron atoms may connect with diamond carbon atoms through chemical bonds which are the driving force to the diamond removal and making diamond convert into graphite. The simulation results demonstrated that, it is possible to mitigate the wear of diamond tools effectively, if those bindings between unpaired d electrons and diamond carbon atoms of the tool can be under control.

Study, analysis, and characterization of ultra-precision diamond tools for single-point diamond turning

2020 ◽  
pp. 251659842096533
Author(s):  
RamaGopal V. Sarepaka ◽  
Sivasakthi Balan ◽  
Somaiah Doodala ◽  
Rakesh Singh Panwar ◽  
D. Rajendra Kotaria
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Single Point ◽  
Quality Parameters ◽  
Diamond Turning ◽  
Radius Of Curvature ◽  
Tool Selection ◽  
Diamond Tools ◽  
Surface Irregularities ◽  
Ultra Precision

In multiple applications of advanced instrumentation, single-point diamond turning (SPDT) is a popular and effective process to generate novel surfaces with nanometric surface roughness and sub-micron surface irregularities, albeit at a high cost. In SPDT, precision diamond tooling contributes significantly to the process cost escalation. Hence, for SPDT, it is vital to have an optimal precision diamond tool deployment. In this article, details of comprehensive precision diamond tool selection and tool characterization are discussed. Three makes of selected ultra-precision diamond (UPD) tools and standard diamond tools (of a global make), designated as CFT, are considered for this study. In this tool bench-marking exercise, the fabrication of Cu–Be alloy predesigned precision components (PDPCs) of a critical geometry is selected. UPD and CFT tools are deployed to fabricate (under similar machining-metrology conditions) the PDPCs. These diamond tools are evaluated in terms of the quality parameters (variation in radius of curvature, form error, and surface roughness) of the workpieces. Further, to explore the progressive wear of these tools, multiple machining cycles are conducted on these workpieces, and their quality parameters are analyzed. Thus, the precision diamond tools of three makes are benchmarked against the CFT tool. Based on the final outcome of this analysis, suitable recommendations are provided to precision diamond tool manufacturers to improve their product in terms of performance and optimized costs to meet the ever-growing tooling demands of the SPDT community.

scholarly journals Measurement and Compensation of Tool Contour Error Using White Light Interferometry for Ultra-Precision Diamond Turning of Freeform Surfaces

2020 ◽  
Vol 14 (4) ◽  
pp. 654-664 ◽  
Author(s):  
Kodai Nagayama ◽  
◽  
Jiwang Yan
Keyword(s):  
White Light ◽  
High Efficiency ◽  
Diamond Tool ◽  
Microlens Array ◽  
Diamond Turning ◽  
Contour Error ◽  
Form Accuracy ◽  
Freeform Optics ◽  
Ultra Precision ◽  
Quick Measurement

In ultra-precision diamond turning of freeform optics, it is necessary to obtain submicron-level form accuracy with high efficiency. In this study, we proposed a new method for the quick measurement and compensation of tool contour errors to improve the form accuracy of the workpiece. In this method, the nanometer-scale contour error of a diamond tool is quickly and precisely measured using a white light interferometer and then compensated for, before machining. Results showed that the contour of a diamond tool was measured with an error less than 0.05 μm peak-to-valley (P-V) and the feasibility of error compensation was verified through cutting experiments to create a paraboloid mirror and a microlens array. The form error decreased to 0.2 μm P-V regardless of the contour error of the diamond tools when cutting the paraboloid mirror, and that of the microlens array was reduced to 0.15 μm P-V during a single machining step.

scholarly journals Simulation and Experimental Study on the Surface Generation Mechanism of Cu Alloys in Ultra-Precision Diamond Turning

Micromachines ◽  
2019 ◽  
Vol 10 (9) ◽  
pp. 573
Author(s):  
Zhang ◽  
Guo ◽  
Chen ◽  
Fu ◽  
Zhao
Keyword(s):  
Tool Wear ◽  
Diamond Tool ◽  
Surface Characteristics ◽  
Diamond Turning ◽  
Generation Mechanism ◽  
Surface Generation ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cu Alloys ◽  
Ultra Precision

The surface generation mechanism of the Cu alloys in ultra-precision diamond turning is investigated by both simulation and experimental methods, where the effects of the cutting parameters on the surface characteristics are explored, including the workpiece spindle speed, the cutting depth, the feed rate and the nose radius of the diamond tool. To verify the built model, the cutting experiments are conducted at selected parameters, where the causes of the error between the simulation and the machining results are analyzed, including the effects of the materials microstructure and the diamond tool wear. In addition, the nanometric surface characteristics of the Cu alloys after the diamond turning are identified, including the finer scratching grooves caused by the tool wear, the formation of the surface burs and the adhesion of graphite. The results show that the built model can be basically used to predict the surface topography for the selection of the appropriate machining parameters in the ultra-precision diamond turning process.

Experiment and Discussion on Ultrasonic Vibration-Assisted Single Point Diamond Turning of Die Steels

2012 ◽  
Vol 497 ◽  
pp. 1-5
Author(s):  
Xiao Dan Xie ◽  
Yong Li ◽  
Cam Vinh Duong ◽  
Ahmed Al-Zahrani
Keyword(s):  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Process ◽  
Die Steels ◽  
Ultra Precision ◽  
Promising Solution ◽  
Vibration Parameters

Traditionally, single point diamond turning (SPDT) can not process ferreous metals because of acute tool wear. Ultrasonic vibration-assisted cutting(UVC) provides a promising solution for the problem. In this paper, for the aim of directly obtaining mirror surface on die steels, UVC method was used combining with SPDT process. Experiments were carried out on an ultra precision turning machine, cutting parameters and vibration parameters were well-chosen, and two kind of feed rates, two kinds of prevailing die steels were experimented. Mirror surfaces were successfully achieved on face turning, with the best roughness of Ra16.6nm. And the surface roughness, surface texture and tool wear in machining process were discussed.

VSPDT: An Optimizer for Single Point Diamond Turning

2007 ◽  
Vol 339 ◽  
pp. 447-452
Author(s):  
Jian Guang Li ◽  
Wing Bun Lee ◽  
Chi Fai Cheung ◽  
Sandy To ◽  
J.J. Du ◽  
...  
Keyword(s):  
New Product Development ◽  
Functional Performance ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Virtual Manufacturing ◽  
Form Error ◽  
Ultra Precision ◽  
Virtual Workpiece ◽  
Optimal Cutting Parameters

Virtual manufacturing (VM), which primarily aimed at reducing the lead times to market and costs associated with new product development, offers various test-beds for the time-consuming and expensive physical experimentation. Since surface roughness and form accuracy play essential roles in the functional performance of the products machined with ultra-precision machining technology. An optimizer, VSPDT (virtual single point diamond turning) system was developed for the purpose of form error compensation and optimal cutting parameters selection. In this paper, the keys issues for developing VSPDT using virtual manufacturing technology were highlighted such as framework of system, virtual workpiece, virtual machining and inspection, etc. At the end of the paper, A VSPDT was developed and applied to predict and compensate the form error, select optimal cutting parameters by using a 2-axis CNC ultra-precision turning machine.

scholarly journals A Simulated Investigation of Ductile Response of GaAs in Single-Point Diamond Turning and Experimental Validation

2020 ◽  
Vol 3 (4) ◽  
pp. 239-250
Author(s):  
Pengfei Fan ◽  
Fei Ding ◽  
Xichun Luo ◽  
Yongda Yan ◽  
Yanquan Geng ◽  
...  
Keyword(s):  
Md Simulation ◽  
Single Point ◽  
Cutting Temperature ◽  
Md Simulations ◽  
Diamond Turning ◽  
Rock Salt Structure ◽  
Zinc Blende ◽  
Salt Structure ◽  
Fundamental Reason ◽  
Zinc Blende Structure

AbstractIn this paper, molecular dynamic (MD) simulation was adopted to study the ductile response of single-crystal GaAs during single-point diamond turning (SPDT). The variations of cutting temperature, coordination number, and cutting forces were revealed through MD simulations. SPDT experiment was also carried out to qualitatively validate MD simulation model from the aspects of normal cutting force. The simulation results show that the fundamental reason for ductile response of GaAs during SPDT is phase transition from a perfect zinc blende structure (GaAs-I) to a rock-salt structure (GaAs-II) under high pressure. Finally, a strong anisotropic machinability of GaAs was also found through MD simulations.

Sign in / Sign up

Export Citation Format

Share Document