Tool wear control in single-crystal diamond cutting of steel by using the ultra-intermittent cutting method |
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| Authors: | YoungChan Song Kentaro Nezu Chun-Hong Park Toshimichi Moriwaki |
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| Affiliation: | 1. Ultra-Precision Machines Team, Intelligent Machine Systems Research Center, Korea Institute of Machinery and Materials, 171 Jang-dong, Yuseong-Gu, Daejeon 305-343, South Korea;2. Sekisui Chemical Co., Ltd., 2-3-17 Toranomon, Minato-ku, Tokyo 105-8450, Japan;3. Department of Industrial and Systems Engineering, Setsunan University, 17-8 Ikedanaka-machi, Neyagawa City, Osaka 572-8508, Japan;1. State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou, 310027, PR China;2. State Key Laboratory of Precision Measuring Technology and Instruments, Centre of MicroNano Manufacturing Technology, Tianjin University, 300072, PR China;3. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, J.S., 210094, PR China;1. State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment, Guangdong University of Technology, Guangzhou, China;2. State Key Laboratory in Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Kowloon, Hong Kong;1. School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China;2. AVIC Harbin Dong’an Engine (Group) Corporation Ltd., Harbin 150066, China |
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| Abstract: | Excessive tool wear is a major drawback to the ultraprecision cutting of steel with geometrically defined single-crystal diamond tools. This paper presents a new approach to reduce this wear. In general, the wear of the diamond tool is due to chemical reactions such as diffusion into the steel, oxidation, graphitization, and carbide formation under cutting conditions of high temperature and high pressure. To suppress these types of chemical reactions, the contact time between the diamond tool and the steel in the cutting process was controlled by intermittent cutting method such as fly-cutting or milling. A series of intermittent cutting experiments were carried out to control the tool–workpiece contact time in one cutting cycle by changing the cutting speed and cutting length in each cutting cycle. The experimental results showed that the diamond tool wear was highly dependent on the tool–workpiece contact time, regardless of the cutting speed, and that the wear was greatly reduced by decreasing the contact time to less than 0.3 ms under these cutting conditions. It is expected that steel can be successfully cut with a single-crystal diamond tool by controlling the tool–workpiece contact time. |
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