A study of the diamond tool wear suppression mechanism in vibration-assisted machining of steel |
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| Affiliation: | 1. Singapore Institute of Manufacturing Technology, 71 Nanyang Drive, Singapore 638075, Singapore;2. Department of Mechanical Engineering, National University of Singapore, 10 Kent Ridge, Singapore 117576, Singapore;1. School of Mechanical Engineering, Yeungnam University, 214-1 Dae-dong, Gyeongsan-si, Gyeongsangbuk-do 712-749, South Korea;2. School of Mechanical Engineering, Universitas Indonesia, Kampus Baru UI, Depok 16424, Indonesia;1. Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Science, Changchun 130033, China;2. Department of Aerospace Engineering, Nagoya University, Nagoya 464-8603, Japan;3. Center for Precision Engineering, Harbin Institute of Technology, Harbin 150001, China;4. Department ofAstronautical and Mechanics, Harbin Institute of Technology, Harbin 150001, China;5. Department of Mechanical Engineering, University of Jeddah, Jeddah 999088, Saudi Arabia;1. State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Technology, Huazhong University of Science and Technology, Wuhan,430074, China;2. Formerly Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, 09661, Germany;1. Department of Mechanical Engineering, National University of Singapore, 10 Kent Ridge Crescent, 9 Engineering Drive 1, Block EA, Singapore 117576, Singapore;2. Singapore Institute of Manufacturing Technology, 71 Nanyang Drive, Singapore 638075, Singapore;3. School of Mechanical Engineering, Shanghai Jiao Tong University, 800 Dongchuan Road, Shanghai 200240, China |
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| Abstract: | Inability of machining steel strongly inhibits the application of diamond machining in manufacturing industry, especially in the fields of ultra-precision and micro machining. In recent years, vibration-assisted machining (VAM) has been proved to be capable of efficiently suppressing the diamond tool wear in cutting steel. Currently, the prevailing speculation claimed by most researchers for such suppression is that the tool–workpiece flash temperature was reduced in VAM, which would slow the chemical reaction between iron on steel and carbon on diamond. However, the correctness of this speculation has not been proved by any experimental or theoretical research. In this paper, in order to understand the true wear suppression mechanism of diamond tools in VAM of steel, a study is conducted by measuring the workpiece temperatures and modeling the cutting energy consumption in both VAM and conventional cutting (CC). Based on the comparison results, it is concluded that the cutting temperature and energy consumption in VAM are not smaller than in CC, and hence the reduced diamond tool wear in VAM should not be caused by the claimed reduced temperature, especially when the material removal rate is very small. Finally, based on the EDS analysis and the comparison of experimental results under different air pressure, two probable reasons are proposed for the significantly reduced diamond tool wear in VAM of steel: (i) increase of gas pressure at the tool–workpiece interface and (ii) generation of an oxide layer on the freshly machined surface. |
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| Keywords: | Vibration-assisted machining Diamond tool wear Cutting temperature Cutting energy consumption |
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