A review of tool wear mechanism and suppression method in diamond turning of ferrous materials

Wang, Jianpeng; Zhang, Guoqing; Chen, Ning; Zhou, Menghua; Chen, Yanbing

doi:10.1007/s00170-021-06700-8

Cited by 26 publications

(6 citation statements)

References 157 publications

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“…The change in edge radius (due to tool wear) will lead to variations in the critical chip thickness ratio. The severity of the tool wear will determine the surface quality (unable to attain nanometric surface roughness with tool wear) [40,41]. DTW is classified into three types: mechanical wear, chemical wear, and physical wear.…”

Section: Tool Wearmentioning

confidence: 99%

Monitoring and Predicting the Surface Generation and Surface Roughness in Ultraprecision Machining: A Critical Review

et al. 2021

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The aim of manufacturing can be described as achieving the predefined high quality product in a short delivery time and at a competitive cost. However, it is unfortunately quite challenging and often difficult to ensure that certain quality characteristics of the products are met following the contemporary manufacturing paradigm, such as surface roughness, surface texture, and topographical requirements. Ultraprecision machining (UPM) requirements are quite common and essential for products and components with optical finishing, including larger and highly accurate mirrors, infrared optics, laser devices, varifocal lenses, and other freeform optics that can satisfy the technical specifications of precision optical components and devices without further post-polishing. Ultraprecision machining can provide high precision, complex components and devices with a nanometric level of surface finishing. Nevertheless, the process requires an in-depth and comprehensive understanding of the machining system, such as diamond turning with various input parameters, tool features that are able to alter the machining efficiency, the machine working environment and conditions, and even workpiece and tooling materials. The non-linear and complex nature of the UPM process poses a major challenge for the prediction of surface generation and finishing. Recent advances in Industry 4.0 and machine learning are providing an effective means for the optimization of process parameters, particularly through in-process monitoring and prediction while avoiding the conventional trial-and-error approach. This paper attempts to provide a comprehensive and critical review on state-of-the-art in-surfaces monitoring and prediction in UPM processes, as well as a discussion and exploration on the future research in the field through Artificial Intelligence (AI) and digital solutions for harnessing the practical UPM issues in the process, particularly in real-time. In the paper, the implementation and application perspectives are also presented, particularly focusing on future industrial-scale applications with the aid of advanced in-process monitoring and prediction models, algorithms, and digital-enabling technologies.

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Section: Tool Wearmentioning

confidence: 99%

Monitoring and Predicting the Surface Generation and Surface Roughness in Ultraprecision Machining: A Critical Review

et al. 2021

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“…The problem of metal-induced catalytic wear of diamond has been studied since the early 1960s. − Many studies have tried to manipulate the surrounding environment of diamond rubbing against ferrous metals to improve the complex friction state and reduce wear at the interface, such as cryogenic cooling, inert gas, ultrasonic vibration, and even the creation of a gaseous carbon-rich (methane) environment. , Additionally, there are also some studies to reduce the mechanochemical wear of the diamond surface by modifying the surface of the rubbing metal. , While these techniques have shown some effectiveness, these approaches require extensive modifications to existing equipment, or the costs of maintaining these special environments are not nearly worth the increase in product life. As a result, they have received limited acceptance by the industry.…”

Section: Introductionmentioning

confidence: 99%

Covalently Bonded Heterostructures with Mixed-Dimensional Carbons for Suppressing Mechanochemical Wear of Diamond under Heavy Loads

Yan,

Chen,

et al. 2024

ACS Appl. Mater. Interfaces

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Diamond is widely acknowledged as the hardest naturally occurring material. Nevertheless, when exposed to friction against ferrous metals, it is prone to graphitization or amorphization, which limits the utilization of its extremely high hardness and wear resistance. These issues have persisted for decades without an effective solution. Here, we report that a covalently bonded heterostructure with mixed-dimensional carbons as a high-performance solid lubricant could effectively reduce diamond surface friction and mechanochemical wear with excellent load capacity and durability. When subjected to dry friction and heavy loads (20–150 N), the heterostructure exhibited a notable improvement over pristine diamond with reduced friction coefficients and relative wear rates by 22–45 and 67–91%, respectively. Especially under a 20 N load, the relative wear rate was an order of magnitude lower than that of pristine diamond. Additionally, experiments and molecular dynamics simulations revealed that the heterostructure integrated the outstanding properties of diamond (three-dimensional (3D)), nanographite (3D), and graphene (two-dimensional (2D)), resulting in improved lubrication and antiwear performance that could not be achieved by the individual carbon materials. The findings in this work will be beneficial to overcome the ferrous metal forbidden zone of diamond and are expected to expand the applications of engineered diamond surfaces and graphite/graphene in tribology, mechanics, and electronic fields.

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“…When the bead wire cuts steel-based materials underwater at a low temperature, the thermal or chemical wear the diamond grain suffered is effectively suppressed. 14 Therefore, mechanical wear is the main cause of diamond grains wear in the subsea cutting.…”

Section: Introductionmentioning

confidence: 99%

Simulation study on mechanical wear of the diamond grain cutting pipeline steel

Zhang

Chen

Liu

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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With the exploitation of marine resources, the development of maintenance operation technology for subsea pipelines transporting oil and gas has become the focus worldwide. Diamond bead wire serves as important engineering equipment in subsea pipeline maintenance, and the study of the wear mechanism of diamond grains on the beads is key to improving the cutting efficiency and lifetime of diamond bead wire. In this work, a theoretical model of the mechanical wear rate of the diamond grain was established, and a simulation model of the diamond grain cutting X65 pipeline steel was developed by applying smoothed particle hydrodynamics method. By studying the effects of the cutting factors of the diamond grain on mechanical wear, the mechanisms of adhesive wear, abrasive wear, and fatigue wear were clarified. The results indicate that the diamond grain in line contact or large surface contact with X65 steel contributes more to wear rate reduction than point contact; The mechanical wear rate predominated by adhesive wear and abrasive wear of the diamond grain increases with the increase of cutting speed and depth. And when the cutting speed is 22–26 m/s and the depth is 20–30 μm, the growing trend of the mechanical wear rate turns gentle, which is more suitable to balance improving cutting efficiency and reducing mechanical wear.

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A review of tool wear mechanism and suppression method in diamond turning of ferrous materials

Cited by 26 publications

References 157 publications

Monitoring and Predicting the Surface Generation and Surface Roughness in Ultraprecision Machining: A Critical Review

Monitoring and Predicting the Surface Generation and Surface Roughness in Ultraprecision Machining: A Critical Review

Covalently Bonded Heterostructures with Mixed-Dimensional Carbons for Suppressing Mechanochemical Wear of Diamond under Heavy Loads

Simulation study on mechanical wear of the diamond grain cutting pipeline steel

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