A Study of the Diamond Tools for Grinding Polycrystalline Diamond

2010 ◽  
Vol 126-128 ◽  
pp. 585-590
Author(s):  
Shenq Yih Luo ◽  
J.K. Ho ◽  
Ming Yi Tsai ◽  
Yi Xian Liu ◽  
William Chen
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
Lower Percentage ◽  
Depth Of Cut ◽  
Workpiece Surface ◽  
Diamond Tools ◽  
Vitrified Bond ◽  
Grinding Efficiency ◽  
Worn Surface

The purpose of this paper was to investigate the grinding performance of two types of cobalt and vitrified bond diamond tools produced by the hot press for the vertical flat grinding polycrystalline diamond. The worn diamond type and the diamond protrusion observed by the toolmaker or SEM after grinding under two different feed rates of 1 and 5 mm/min and the depth of cut of 2 µm with total depth of 10µm were studied. In addition, the grinding efficiency and the workpiece surface roughness produced were analyzed as well. The experiment results showed that when the feed rate of 1 mm/min during the flat grinding PCD was used, a lower percentage of the good diamond, a higher percentage of flat diamond and pulled-out hole on the worn surface of the cobalt bond diamond tool were obtained. For the vitrified bond diamond tool, the good diamond produced showed a higher percentage and flat grit and pulled-out hole displayed a relatively lower percentage. This may be due to the result of the relatively moderate strength and grit retention of the vitrified bond. Furthermore, the diamond protrusion and the grinding efficiency produced for the vitrified bond diamond tool were better than those for the cobalt bond tool. And the PCD surface roughness obtained was better as well.

scholarly journals Machinability of Rolled Aluminum using Advanced Coated Cutting Tools and its Characterization

2019 ◽  
Vol 8 (3) ◽  
pp. 776-783
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Diamond Tool ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
Constant Depth ◽  
Rolled Aluminum ◽  
Polycrystalline Diamond Inserts

Because of multiple properties like higher values of corrosion resistance, formability, weldability along with greater structural utility aluminum alloys are generally gaining more and more demand in industries and household. With this the requirement for searching of higher quality cutting tool to machine aluminum is also growing. Here different cutting tools like MTCVD+TiCN+Al2O3 , MTCVD+TiCN+Al2O3+TiOCN, MTCVD+TiN+TiCN+Al2O3+TiN, PVD AlTiN, cemented carbide (k-10) insert brazed with Polycrystalline Diamond and Polycrystalline Diamond Inserts are being used to machine rolled aluminum in dry condition and then comparative analysis are made. The cutting is of orthogonal type and capstan lathe is used for the same. Under different conditions of cutting the surface roughness along with morphology of chip are analyzed. Under constant depth of cut (doc) along with variable velocities and feed, the turning operation is performed. With SEM and XRD the identification including characterization of cutting tool were also performed. The polycrystalline diamond tool is found to give optimum surface finish, thin type of chip along with mirror like finish during machining operation.

Small Holes Fabrication on Soda Glass by Self-Elastic Polycrystalline Diamond Tool

2012 ◽  
Vol 516 ◽  
pp. 516-521
Author(s):  
Chung Chieh Cheng ◽  
Dong Yea Sheu
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
The Self ◽  
High Quality ◽  
Drilling Tool ◽  
Drilling Tools ◽  
Absorbing Materials ◽  
New Type ◽  
Small Holes

This study describes a novel process to drill small holes in brittle materials such as glass, silicon and ceramic using a self-elastic polycrystalline diamond (PCD) drilling tool. In order to improve the surface roughness and reduce crack of the small holes, a new type of self-elastic PCD drilling tool equipped with vibration absorbing materials inside the housing was developed to fabricate small holes in glass in this study. The self-elastic PCD drilling tools could absorb the mechanical force by the vibration absorbing materials while the PCD tool penetrates into the small holes. Compared to conventional PCD drilling tools, the experimental results show that high-quality small holes drilled in glass can be achieved with cracking as small as 0.02mm on the outlet surface using the self-elastic PCD drilling tool.

A Truing Technique of Flattening Diamond Grains for Fabricating Microstructures with Fine Surfaces

2008 ◽  
Vol 389-390 ◽  
pp. 350-355
Author(s):  
Takeshi Harada ◽  
Takuya Semba
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Diamond Tool ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
Mesh Size ◽  
Diamond Disk ◽  
Working Surface ◽  
Work Material ◽  
Tool Profile

A truing technique that can be used to shape the tip of an electroformed diamond tool into a hemisphere and flatten diamond grains on the tool working surface at the same level as the bond face was developed. A polycrystalline diamond disk whose top surface roughened by electrical discharge machining was partially flattened by grinding was used as a truer. Diamond grains on the tool working surface were successfully flattened along the hemispherical tool profile when the grains mesh size of #1000 was employed. In addition, a grinding test using glasslike carbon as a work material revealed that a surface roughness of less than 50 nm Rz could be obtained in both cases when moving the tool on contour and scanning paths.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

An Experimental Investigation of the Laser Milling Process for Polycrystalline Diamonds

2011 ◽  
Vol 291-294 ◽  
pp. 810-815 ◽  
Author(s):  
Qi Wu ◽  
Jun Wang
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Polycrystalline Diamond ◽  
Milling Process ◽  
Depth Of Cut ◽  
Good Surface ◽  
Laser Milling ◽  
Cavity Profile ◽  
Profile Depth ◽  
Good Surface Finish

An experimental study of the pulsed laser milling process for a sintered polycrystalline diamond is presented. The characteristics and quality of the cavities machined with a Yd laser under different pulse energies, pulse overlaps, scan overlaps and numbers of passes are discussed, together with the effects of these parameters on the cavity profile, depth of cut and surface roughness. A statistical analysis is also presented to study the relationship between the process parameters and surface roughness. It shows that the optimum pulse overlap and pulse energy may be used to achieve good surface finish, whereas scan overlap and number of passes can be selected to improve the depth of cut without much effect on the surface finish.

scholarly journals Pengaruh Kecepatan dan Kedalaman Potong pada Proses Pembubutan Konvensional Terhadap Kekasaran Permukaan Lubang

2018 ◽  
Vol 3 (2) ◽  
pp. 82-86
Author(s):  
Bambang Siswanto ◽  
Sunyoto Sunyoto
Keyword(s):  
Surface Roughness ◽  
Descriptive Analysis ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cylinder Block ◽  
Depth Of Cut ◽  
Cast Aluminum ◽  
Turning Process ◽  
Workpiece Surface ◽  
Independent Variables

There are several factors that affect the roughness of the workpiece surface when doing turning process on the lathe, especially the use of cutting parameters. This study aims to determine the effect of cutting speed and depth of cut parameters on the roughness of cylinder block hole surface. This research is an experimental research using two independent variables, which are cutting speed and depth of cut. The dependent variable is surface roughness of cylinder block’s hole. The research was done by making cast aluminum specimens and then turning a hole in the specimen with varied cutting speed and depth of cut. The surface roughness was then tested using Surfcorder SE 300. The obtained data were analyzed using descriptive analysis. Results show that there is an effect of cutting speed on the surface roughness of cylinder block, with the best result (smallest roughness value) was obtained from the use of cutting speed of 125 m / min. There is also an effect of depth of cut on the surface roughness of the cylinder block, with the best result given from the use of a 0.2 mm depth of cut.Ada beberapa faktor yang mempengaruhi tingkat kekasaran permukaan benda kerja pada proses pembubutan. Penelitian ini bertujuan untuk mengetahui pengaruh parameter kecepatan potong dan kedalaman potong terhadap kekasaran permukaan pada pembubutan lubang blok silinder mesin pemotong rumput. Penelitian ini merupakan penelitian eksperimen dengan variabel bebas kecepatan potong dan kedalaman potong, dan variabel terikat kekasaran permukaan lubang. Penelitian dilakukan dengan pembuatan spesimen dengan proses pengecoran aluminium kemudian spesimen dibubut lubang dengan diberi variasi kecepatan potong dan variasi kedalaman potong. Hasil pembubutan dilakukan uji kekasaran menggunakan Surfcorder SE 300. Data yang diperoleh kemudian dianalisis dengan analisis deskriptif. Hasil penelitian menunjukkan bahwa ada pengaruh kecepatan potong terhadap hasil kekasaran permukaan blok silinder mesin pemotong rumput, hasil  paling baik dengan nilai kekasaran paling kecil diperoleh dari kecepatan potong 125 m/menit. Ada pengaruh kedalaman potong terhadap hasil kekasaran permukaan blok silinder mesin pemotong rumput, hasil paling baik dengan nilai kekasaran paling kecil diperoleh dari kedalaman potong 0,2 mm.

scholarly journals Correlation between surface roughness and AE signals in ceramic grinding based on spectral analysis

2018 ◽  
Vol 249 ◽  
pp. 03003 ◽  
Author(s):  
M A Aulestia Viera ◽  
F A Alexandre ◽  
P R Aguiar ◽  
R B Silva ◽  
E C Bianchi
Keyword(s):  
Surface Roughness ◽  
Frequency Domain ◽  
Surface Condition ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Process Conditions ◽  
Workpiece Surface ◽  
Grinding Conditions ◽  
Grinding Machine ◽  
Frequency Domain Techniques

The study and monitoring of the workpiece surface roughness is one of the most important parameters of the grinding process. This paper proposes a method for analysing the surface condition of ground ceramic components by means of the acoustic emission (AE) signal analysis along with frequency domain techniques. Tests were performed using a surface-grinding machine equipped with a resin-bond diamond grinding wheel, where signals were collected at 2 MHz. Alumina workpieces were machined under six different depth of cut values, covering slight, medium and severe grinding conditions. Frequency content was studied in order to select bands closely related to the process conditions. An analysis of the root mean square values (RMS) of the signals was performed, seeking for a correlation with the surface roughness. Digital filters were applied to the raw signals. The RMS values filtered for two frequency bands presented a better fitting to the linear regression, which is highly desirable for setting a threshold to detect the workpiece surface conditions and implementing into a monitoring system. Results showed that the amplitude of the signals presented different characteristics in the frequency domain according to the workpiece surface condition. It was also observed a higher spectral activity in the severe grinding conditions.

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.

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