Diamond tool wear when machining Al6061 and 1215 steel

Abstract Different rates of wear of diamond tools depend on the physical and chemical nature of the workpiece material. Wear mechanisms for diamond tools can be either abrasive or chemical in nature, or a combination thereof. Differentiating the affects of these wear mechanisms can be accomplished by measuring the wear geometry of the cutting edge as a function of cutting distance. Orthogonal cutting experiments using 6061 aluminum and 1215 steel were conducted to illustrate abrasive and abrasive plus chemical wear, respectively. Wear of the diamond tool was measured using the electron beam induced deposition method. This method provides nanometer resolution images of the tool edge (edge radius and wear land) that can be used to calculate volumetric wear loss and wear rates. A method for determining the Archard wear coefficient for diamond turning based on measured wear and cutting forces is also introduced. Comparisons are made between the tool wear resulting from the two materials, and hypotheses related to the wear mechanism are presented.

[1]  C. Arcona,et al.  An Empirical Tool Force Model for Precision Machining , 1998 .

[2]  A. Molinari,et al.  Modeling of tool wear by diffusion in metal cutting , 2002 .

[3]  Richard E. DeVor,et al.  A NEW MECHANISTIC MODEL FOR PREDICTING WORN TOOL CUTTING FORCES , 2001 .

[4]  Akira Kobayashi,et al.  Measuring the Very Small Cutting-Edge Radius for a Diamond Tool Using a New Kind of SEM Having Two Detectors , 1990 .

[5]  Satoshi Kiyono,et al.  Nanometer edge profile measurement of diamond cutting tools by atomic force microscope with optical alignment sensor , 2006 .

[6]  J. Wilks,et al.  The wear of diamond tools turning mild steel , 1980 .

[7]  J. Wilks,et al.  Clean surface reactions between diamond and steel , 1978, Nature.

[8]  E. Wilks,et al.  Properties and Applications of Diamond , 1991 .

[9]  Paul Mativenga,et al.  Heat generation and temperature prediction in metal cutting: A review and implications for high speed machining , 2006 .

[10]  J. Drescher.  Scanning electron microscopic technique for imaging a diamond tool edge , 1993 .

[11]  Christopher J. Evans,et al.  Chemical aspects of tool wear in single point diamond turning , 1996 .

[12]  M. E. Merchant.  Mechanics of the Metal Cutting Process. I. Orthogonal Cutting and a Type 2 Chip , 1945 .

[13]  Richard E. DeVor,et al.  An Evaluation of Ploughing Models for Orthogonal Machining , 1999 .

[14]  Taylan Altan,et al.  Estimation of tool wear in orthogonal cutting using the finite element analysis , 2004 .

[15]  D. Crompton,et al.  The wear of diamond , 1973, Proceedings of the Royal Society of London. A. Mathematical and Physical Sciences.

[16]  Kui Liu,et al.  Nano-precision measurement of diamond tool edge radius for wafer fabrication , 2003 .

[17]  A. Gangopadhyay,et al.  Friction and wear behavior of diamond films against steel and ceramics , 1993 .

[18]  Generalization of the Lee-Shaffer solution in the theory of metal cutting , 2008 .

[19]  M. C. Shaw.  Metal Cutting Principles , 1960 .