Cutting performance of diamond tools during ultra-precision turning of electroless-nickel plated die materials

Abstract

This study is an attempt (a) to observe the wear characteristic of diamond tool with 200 km cutting distance and to study the effects of wear on the surface roughness and cutting forces and (b) to optimize various cutting parameters such as depth of cut, feed rate, spindle speed and phosphorus content. The experimental results showed that tool wear was not so significant although some defects on rake face were observed after cutting 15.6km. Further cutting showed that the surface roughness increases with cutting distance, and that the cutting forces were larger than thrust force at the beginning of cutting, but after cutting 130km thrust force became larger and increased rapidly. It was also observed that forces increase with the increase of depth of cut, spindle speed and feed rate, and decrease with the increase of phosphorus content of the plating. Depth of cut has no significant effect on surface roughness, while it increases with increase of feed rate and decreases with the increase of percentage of phosphorus content in the workpieces. In case of spindle speed, surface roughness decreases with the increase of spindle speed up to a certain value and then starts to increase with the increase of spindle speed.

Microgrooving on electroless nickel plated materials using a single crystal diamond tool

“…Initially, the cutting edge radius of the tool was measured as about 22 nm, which became about 43 nm after reaching 50 km of the cutting distance. This increase in cutting edge radius might cause the thrust forces to increase significantly with the cutting distance [9]. Optical observation of the tool did not reveal any significant wear to affect the forces.…”

Multi objective optimisation of thermally enhanced machining parameters of Inconel 718 using grey relational analysis

“…Considering the feed and depth of cut, it is observed that the parameters are complimenting the surface roughness. The feed trend is commonly observed in machining research and it effect is ascribed to the prominent effect of tool profile marks on machined surface resulting in poor surface finish (Pramanik et al, 2003). The effect can also be reasoned due to shift of material towards brittle mode machining at high feed rate.…”

Ultra-precision turning of electroless-nickel: Effect of phosphorus contents, depth-of-cut and rake angle

“…Hence, the effect of machining parameters on machined MMC surface may be different to that on a non-reinforced material surface. The theoretical roughness of a turned surface (due to feed marks) can be calculated by using the following equations [12,33]:…”

“…Fig. 17(a) shows that the residual stress (longitudinal) is tensile (10-100 MPa) in machined surface of the non-reinforced alloy and compressive (3)(4)(5)(6)(7)(8)(9)(10)(11)(12) in that of the MMC for the considered range of speeds. Longitudinal residual stress for non-reinforced alloy is low at lower cutting speed and it increases at a high rate with the increase of speed and then reaches a constant value.…”

“…To overcome these problems, aluminium alloys reinforced by ceramic particles, known as metal matrix composites (MMCs), have been developed [2][3][4][5][6][7][8][9]. Nevertheless, the incorporation of the hard particles makes the machining of MMCs difficult [10,11], and diamond tools are often necessary [8,[12][13][14].…”