Diamond Tool Wear Reduction by Combining Ultrasonic Elliptical Vibration with Graphite Particle Atmosphere

2014 ◽  
Vol 1027 ◽  
pp. 32-35 ◽  
Author(s):  
Xing Gao ◽  
Chao Jiang Li ◽  
Yong Li ◽  
Cam Vinh Duong
Keyword(s):  
Tool Wear ◽  
Graphite Particle ◽  
Diamond Tool ◽  
Combined Method ◽  
Die Steel ◽  
Elliptical Vibration ◽  
Ultra Precision ◽  
Vibration Mechanism ◽  
Wear Reduction ◽  
Ultrasonic Elliptical Vibration

For reducing diamond tool wear in ultra-precision cutting of ferrous metals, a process of combining ultrasonic elliptical vibration with graphite particle atmosphere was put forward. An experimental setup was built integrating an ultrasonic elliptical vibration mechanism with a jet lubrication device on a 4-axis ultra-precision lathe. The frequency of ultrasonic elliptical vibration is 38.36 kHz with a trajectory of 8.5×3.5μm. Graphite particles with sizes of 1.3~2μm were selected. Conventional cutting and the combined method were conducted on die steel. Compared with conventional cutting with a wear land width of about 300μm, diamond tool wear in the combined method was decreased to about 20 to 30μm. The combined method is feasible to further reduce the diamond tool wear when cutting die steel.

Design of an ultrasonic elliptical vibration device with two stationary points for ultra-precision cutting

Ultrasonics ◽  
2021 ◽  
pp. 106662
Author(s):  
Wei Bai ◽  
Kai Wang ◽  
Dongxing Du ◽  
Jianguo Zhang ◽  
Wen Huang ◽  
...  
Keyword(s):  
Stationary Points ◽  
Elliptical Vibration ◽  
Ultra Precision ◽  
Ultrasonic Elliptical Vibration

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.

Mirror Surface Machining of Steel by Elliptical Vibration Cutting with Diamond-Coated Tools Sharpened by Pulse Laser Grinding

2018 ◽  
Vol 12 (4) ◽  
pp. 573-581 ◽  
Author(s):  
Hiroshi Saito ◽  
Hongjin Jung ◽  
Eiji Shamoto ◽  
Shinya Suganuma ◽  
Fumihiro Itoigawa ◽  
...  
Keyword(s):  
Low Cost ◽  
Mirror Surface ◽  
Elliptical Vibration Cutting ◽  
Surface Machining ◽  
Vibration Cutting ◽  
Die Steel ◽  
Elliptical Vibration ◽  
Coated Tools ◽  
Ultrasonic Elliptical Vibration ◽  
Rapid Tool

Low-cost mirror surface machining of die steel is proposed in this research by applying elliptical vibration cutting with diamond-coated tools sharpened by pulse laser grinding (PLG). It is well known that conventional diamond cutting cannot be applied to die steel owing to rapid tool wear. Several attempts have been reported to prevent rapid tool wear, such as using ultrasonic elliptical vibration cutting. The ultrasonic elliptical vibration cutting developed by the authors to achieve mirror surface finish on die steel and prevent rapid wear is widely used in the industry. However, high-cost single-crystalline diamond tools that are finished using a time-consuming lapping process are required to obtain mirror surfaces. The authors, meanwhile, have recently developed the PLG process to efficiently sharpen the cutting edges of hard tool materials such as cubic boron nitride. Therefore, a practical mirror surface machining method for die steel is proposed in this research, namely elliptical vibration cutting with low-cost diamond-coated tools sharpened by the efficient PLG process. The results of the machining experiments confirmed that practical mirror surface machining of die steel can be achieved by the proposed method.

Cutting Force Evolution and its Power Spectrum Analysis with Tool Wear Progress in Ultra-Precision Raster Milling

2014 ◽  
Vol 625 ◽  
pp. 20-25
Author(s):  
Guo Qing Zhang ◽  
Suet To ◽  
Gao Bo Xiao
Keyword(s):  
Power Spectrum ◽  
Tool Wear ◽  
Cutting Force ◽  
Spectrum Analysis ◽  
Diamond Tool ◽  
Power Spectrum Analysis ◽  
Spectrum Density ◽  
Ultra Precision ◽  
The Time Domain ◽  
Cutting Experiments

In this paper, cutting force and its power spectrum analysis at different tool wear levels are explored. A dynamic model is established to simulate the measured cutting force compositions, and a series of cutting experiments have been conducted to investigate the cutting force evolution with the tool wear progress. Research results reveal that in the time domain, the cutting force in UPRM is characterized as a force pulse follows by a damped vibration signals, the vibration can be modeled by a second order impulse response of the measurement system. While in the frequency domain, it is found that the power spectrum density at the natural frequency of dynamometer increases with the progress of tool wear, which therefore can be utilized to monitor diamond tool wear in UPRM.

A Novel Tool Wear Measurement Method in Ultra-Precision Raster Milling

2016 ◽  
Vol 679 ◽  
pp. 123-127 ◽  
Author(s):  
Guo Qing Zhang ◽  
Suet To
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Diamond Tool ◽  
Experimental Result ◽  
Chip Surface ◽  
Wear Characteristics ◽  
The Past ◽  
Wear Measurement ◽  
Ultra Precision ◽  
Groove Cutting

Tool wear measurement has drawn a significant of attention in the past decades. However, no research has been found on the investigation of tool wear measurement in ultra-precision raster milling (UPRM) process since it is a relative complex cutting process. In the present study, tool wear characteristics were identified by using cutting chip morphologies and a groove cutting. Tool wear investigation using cutting chips is effective because diamond tool wear characteristics can be directly imprinted on the cutting chip surface. Through the inspection of chip surfaces, the profile and location of the tool fracture can be identified. Also, through the groove cutting, the cutting edge retreat due to the tool flank wear can be identified. In this research, a mathematical model was established to calculate the tool retreat. The experimental result shows that the proposed tool wear investigation method is an effective method.

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.

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.

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