Tool wear control in single-crystal diamond cutting of steel by using the ultra-intermittent cutting method

Song, Young-Chan; Kentaro, Nezu; Park, Chun-Hong; Moriwaki, Toshimichi

doi:10.1016/j.ijmachtools.2008.10.014

Cited by 68 publications

(13 citation statements)

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“…While using diamond to manufacture rope saws and segmental cut-off wheels for cutting steel and cast iron is undesirable due to the chemical wear caused by diamond graphitization, synthetic diamond powders are still rather widely used as SHMs [26,27]. The effect of the chemical wear of SHM on the performance of a tool can be reduced by partial replacement of the diamond in the tool's working layer with cBN, which is chemically inert to Fe [28].…”

Section: Hybrid Diamond/cbn Cutting Tools: Optimization Of Compositiomentioning

confidence: 99%

“…This wear results from diamond graphitization followed by carbon diffusion to the material being treated. To develop high quality cutting tools for steels and cast irons, two problems need to be addressed: 1 -to increase the hardness, strength and impact resistance of a binder and ensure its ability to securely retain the SHM grain [23][24][25]; 2 -to ensure the undamaged condition and integrity of SHM grains for the low wear of the binder.While using diamond to manufacture rope saws and segmental cut-off wheels for cutting steel and cast iron is undesirable due to the chemical wear caused by diamond graphitization, synthetic diamond powders are still rather widely used as SHMs [26,27]. The effect of the chemical wear of SHM on the performance of a tool can be reduced by partial replacement of the diamond in the tool's working layer with cBN, which is chemically inert to Fe [28].…”

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Diamond and cBN hybrid and nanomodified cutting tools with enhanced performance: Development, testing and modelling

et al. 2015

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Abstract:The potential of the enhancement of superhard cutting tool performance on the basis of microstructural modifications of the tool materials is studied. Hybrid machining tools with mixed diamond and cBN grains, and machining tools with composite nanomodified metallic binders are developed, and tested experimentally and numerically. It is demonstrated that both combinations of diamond and cBN (hybrid structure) and nanomodification of the metallic binder (with hexagonal boron nitride/hBN platelets) lead to sufficient improvement in the machining performance. Superhard tools with 25% of the diamond replaced by cBN grains demonstrate 20% increased performance as compared with pure diamond machining tools, and more than two times higher performance compared with pure cBN tools. Furthermore, the machining efficiency of the wheels modified by hBN particles was 80 % more efficient compared with the tools with the original binder. A computational model of hybrid superhard tools is developed, and applied to the analysis of the structure-performance relationships of the tools.Keywords: Composites; Nanoreinforcement; Machining tool IntroductionThe productivity of cutting tools from superhard materials (SHM) determines the quality and costs of manufacturing many industrial products. The performance of machining tools depends to a large degree on the microstructural parameters of the tools, e.g., binder properties, cutting grain distribution and strength, and grain/binder bonding [1][2][3][4][5][6].The problem of the enhancement of material properties by tailoring material structures is one of the most important challenges of materials science [7]. Still, the microstructural improvement of machining tools, including nanostructuring and hybridization, is a relatively new subject.In this paper, we seek to explore the potential effects of hybrid and nanomodified structures of Hybrid diamond/cBN cutting tools: Optimization of composition and structuresDiamond monocrystals are typical abrasive elements of segmental cut-off wheels for concrete cutting. Their advantages over other SHMs include their high hardness as well as static and dynamic strength. Because cutting using cut-off wheel tools is performed at 1500-3000 revolutions per minute (rpm), the ability of SHM grains to stay intact under constant 3 mechanical loads is essential. The resistance of SHMs to chemical wear is also critical for cutting steel or cast iron. This wear results from diamond graphitization followed by carbon diffusion to the material being treated. To develop high quality cutting tools for steels and cast irons, two problems need to be addressed: 1 -to increase the hardness, strength and impact resistance of a binder and ensure its ability to securely retain the SHM grain [23][24][25]; 2 -to ensure the undamaged condition and integrity of SHM grains for the low wear of the binder.While using diamond to manufacture rope saws and segmental cut-off wheels for cutting steel and cast iron is undesirable due to the chemical wear caused by diamond grap...

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Section: Hybrid Diamond/cbn Cutting Tools: Optimization Of Compositiomentioning

confidence: 99%

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confidence: 99%

Diamond and cBN hybrid and nanomodified cutting tools with enhanced performance: Development, testing and modelling

et al. 2015

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“… The EFCS system only adopts part of the cutting cycle, resulting in the interrupted nature of the process. This enables sufficient cooling of the diamond tool in cutting, which might be beneficial for extending tool life [15] and [16].…”

Section: Uniqueness Of the Efcs Systemmentioning

confidence: 99%

Novel end-fly-cutting-servo system for deterministic generation of hierarchical micro–nanostructures

Zhu

Zeng

2015

CIRP Annals

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This paper reports on the diamond cutting based generation of hierarchical micronanostructures, which are conventionally difficult for both mechanical and non-mechanical methods to achieve. A novel end-fly-cutting-servo (EFCS) system, with four-axis servo motions that combine the concepts of fast/slow tool servo and endface fly-cutting, is proposed and investigated. In the EFCS system, an intricately shaped primary surface is generated by material removal, while the desired secondary nanostructures are simultaneously constructed using residual tool marks by actively controlling tool loci. The potential of the EFCS system is demonstrated firstly by fabricating a nanostructured F-theta freeform surface and a nanostructured micro-aspheric array.

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“…Several technological methods have been proposed for overcoming this serious tool wear issue: turning of medium carbon steels in different carbon-saturated atmospheres [6,7]; turning of stainless steels in a low temperature environment [8]; adopting the ultrasonic vibration assisted turning technique to decrease the cutting force and temperature for controlling tool wear and obtaining optical-quality surface [9,10]; restraining the chemical reactions between carbon atoms and iron atoms at high temperature by surface modification of the diamond tool and workpiece materials [11]; and proposing an ion-shot coolant method for micro-cutting of ferrous materials [12].…”

Section: Introductionmentioning

confidence: 99%

Thermochemical Wear of Single Crystal Diamond Catalyzed by Ferrous Materials at Elevated Temperature

et al. 2017

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Abstract:Single crystal diamond has been recognized as the optimal tool material in ultra-precision machining. However, the excessive tool wear prevents it from cutting ferrous materials. This paper conducts a series of thermal analysis tests under the conditions of different gas atmospheres, heating temperatures, crystallographic planes and workpiece materials, in order to clarify the details of thermochemical wear of diamond catalyzed by iron at elevated temperature. Raman scattering analysis was performed to identify the transformation of diamond crystal structure. Energy dispersive X-ray analysis was used to detect the change in chemical composition of the work material. X-ray photoelectron spectroscopy was adopted to confirm the resultants of interfacial thermochemical reactions. The experimental results revealed that the diamond wear included the graphitization, diffusion and oxidation. Temperature was considered as the key factor affecting these wear mechanisms. The initial graphitization temperatures of diamond catalyzed by iron under different conditions were obtained, and the graphitized degree relied heavily on the crystallographic plane while being insensitive to the workpiece material. The diffusion wear rule was preliminarily achieved by the established prediction model of the carbon atoms diffusing into the iron lattice, and the types and resultants of interfacial chemical reactions were deduced.

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Tool wear control in single-crystal diamond cutting of steel by using the ultra-intermittent cutting method

Cited by 68 publications

References 10 publications

Diamond and cBN hybrid and nanomodified cutting tools with enhanced performance: Development, testing and modelling

Diamond and cBN hybrid and nanomodified cutting tools with enhanced performance: Development, testing and modelling

Novel end-fly-cutting-servo system for deterministic generation of hierarchical micro–nanostructures

Thermochemical Wear of Single Crystal Diamond Catalyzed by Ferrous Materials at Elevated Temperature

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