Experimental study on the effects of feed rate and tool geometries on tool wear in diamond cutting of sinusoidal microstructured surfaces

Abstract

Tool wear in diamond cutting of sinusoidal microstructured surfaces with a fast tool servo (FTS) may be quite different from that in the conventional diamond turning process, as the depth of cut changes periodically along the contour of the cutting surface and diamond tools with a sharp point tip are used. According to a theoretical analysis of the machining of sinusoidal surfaces, feed rate is a key cutting parameter affecting tool wear. In the current paper, a series of controlled cutting tests of LY12 aluminium alloy with different feed rates was executed on a two-axis bench-type ultra-precision turning machine equipped with an FTS device. The machined surface quality and dynamic cutting forces were measured and analysed. Tool wear patterns were investigated for various feed rates. It is essential to discuss the cutting stress borne by the diamond tool in the cutting of sinusoidal surfaces, since transformation of diamond to graphite induced by high pressure has been proved in previous works. The maximum normal stress acting on the rake face was deduced from measured dynamic cutting forces. Micro-Raman spectroscopy was adopted for analysing materials on tool tips. The experimental results showed that graphite appeared at the tool tip for some feed rates in the cutting of sinusoidal surfaces. The effects of tool geometry on tool wear are also shown.

Review of recent advances on energy efficiency of machine tools for sustainability

“…Many efforts have been paid on this issue in recent years. 22–28 Aiming at maximum production rate, general milling operations and multi-pass milling operations were modeled to determine the optimal cutting parameters. 25,26 The optimal cutting parameters under various machining conditions were solved by geometric programming algorithm.…”

Effect of cutting parameters on surface quality during diamond turning of micro-prism array

“…6 Ultra-precision diamond turning is considered as a deterministic nanoscale machining process using ultra-sharp singlecrystal diamond tools, 7 and it has been recognized as the best option in roller mold manufacturing because the diamond tool possesses the super hardness and high resistance to wear, and the high-quality optical surface and sub-micron form accuracy can be achieved on nonferrous materials. 8,9 Early efforts of many researchers have laid a good foundation for diamond turning of microstructured surfaces to the current stage. Brinksmeier et al 10 have developed a nano fast tool servo (nFTS)-assisted diamond turning process to machine microstructures with nanometer precision, which could improve the surface quality of diffractive optical elements.…”

“…6 Ultra-precision diamond turning is considered as a deterministic nanoscale machining process using ultra-sharp single-crystal diamond tools, 7 and it has been recognized as the best option in roller mold manufacturing because the diamond tool possesses the super hardness and high resistance to wear, and the high-quality optical surface and sub-micron form accuracy can be achieved on nonferrous materials. 8,9…”

Tool path optimal design for slow tool servo turning of complex optical surface

“…Besides, machining parameters, control system algorithm and tool–workpiece vibration have significant effects on the tool wear and machining accuracy, so relevant research for STS/FTS was also studied. 2 –4…”