Advertisement

Steady tool wear and its influence on tool geometry in ultra-precision fly cutting of CuZn30

  • Guoqing Zhang
  • Suet To
  • Xiaoyu Wu
  • Yan Lou
ORIGINAL ARTICLE
  • 4 Downloads

Abstract

In ultra-precision fly cutting (UPFC), steady tool wear progresses gradually when cutting ductile materials. The steady wear of diamond tools changes the tool geometry, and further affects the topography of the machined surface. In this study, a theoretical and experimental investigation was conducted on the forms of steady tool wear and their influence on the tool geometry in UPFC. The features of steady tool wear in UPFC were investigated, the displacement of the cutting edge under the effects of tool flank wear was modeled, and factors affecting the cutting edge roundness were investigated. The study results indicate the following: (1) the features of steady tool wear in UPFC include crater wear on the rake face, smooth and flat wear on the cutting edge, and flank wear on the tool clearance face. (2) A smooth wear-land on the cutting edge changes the top rake of the cutting tools, whereas flank wear on the tool clearance face affects the clearance angle and roundness of the cutting edge. (3) The maximum width of the tool material loss zone, the nose radius of the original fresh cutting edge, and the arc angle of the wear-land have a certain influence on the nose radius of the worn cutting edge. The results of this study will provide deep insight into steady tool wear and its influence on the tool geometry, which can potentially be used to predict or evaluate the finish of a machined surface under tool steady wear.

Keywords

Ultra-precision fly cutting Tool wear Tool geometry Cutting edge roundness 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

This work was supported by the National Natural Science Foundation of China under Grant (51505297, 51575360 and 51675347); the Natural Science Foundation of Guangdong Province under Grant (2017A030313295 and 2014A030310261); the Shenzhen Science and Technology Program under Grant (JCYJ20160422170026058); and the Shenzhen Peacock Technology Innovation Project under Grant (KQJSCX20170727101318462).

References

  1. 1.
    Zhang Y, Zhou Z, Lv Y, Wang J, Shao L, Iqbal A (2013) Wear behavior of natural diamond tool in cutting tungsten-based alloy. Int J Adv Manuf Technol 69(1–4):329–335CrossRefGoogle Scholar
  2. 2.
    Shaw MC, Cookson JO (2005) Metal cutting principles. Oxford University Press, Oxford, New YorkGoogle Scholar
  3. 3.
    Stephenson DA, Agapiou JS (2006) Metal cutting theory and practice, Second edn. Taylor & Francis Group CRC press, Boca Raton, Florida.Google Scholar
  4. 4.
    ISO 3685-1993(E) (1993) Tool life testing with single point turning tools. ISO standardGoogle Scholar
  5. 5.
    Yazu S, Nakai T (1991) Tool application of diamond and cbn. Mater Sci Monogr 73:37–41CrossRefGoogle Scholar
  6. 6.
    Cheung CF, Lee WB (2002) Prediction of the effect of tool interference on surface generation in single-point diamond turning. Int J Adv Manuf Technol 19(4):245–252CrossRefGoogle Scholar
  7. 7.
    Tian F, Yin Z, Li S (2016) A novel long range fast tool servo for diamond turning. Int J Adv Manuf Technol 86(5–8):1–8Google Scholar
  8. 8.
    Mir A, Luo X, Cheng K, Cox A (2018) Investigation of influence of tool rake angle in single point diamond turning of silicon. Int J Adv Manuf Technol 94(5–8):2343–2355CrossRefGoogle Scholar
  9. 9.
    Zhang Z, Yan J, Kuriyagawa T (2011) Study on tool wear characteristics in diamond turning of reaction-bonded silicon carbide. Int J Adv Manuf Technol 57(1–4):117–125CrossRefGoogle Scholar
  10. 10.
    Durazo-Cardenas I, Shore P, Luo X, Jacklin T, Impey SA, Cox A (2007) 3d characterization of tool wear whilst diamond turning silicon. Wear 262:340–349CrossRefGoogle Scholar
  11. 11.
    Cheng K, Luo X, Ward R, Holt R (2003) Modeling and simulation of the tool wear in nanometric cutting. Wear 255:1427–1432CrossRefGoogle Scholar
  12. 12.
    Palanikumar K, Davim JP (2009) Assessment of some factors influencing tool wear on the machining of glass fibre-reinforced plastics by coated cemented carbide tools. J Mater Process Technol 209:511–519CrossRefGoogle Scholar
  13. 13.
    Kılıçkap E, Çakır O, Aksoy M, İnan A (2005) Study of tool wear and surface roughness in machining of homogenised sic-p reinforced aluminium metal matrix composite. J Mater Process Technol 164:862–867CrossRefGoogle Scholar
  14. 14.
    Zhou M, Ngoi BKA, Yusoff MN, Wang XJ (2006) Tool wear and surface finish in diamond cutting of optical glass. J Mater Process Technol 174:29–33CrossRefGoogle Scholar
  15. 15.
    Jia P, Zhou M (2012) Tool wear and its effect on surface roughness in diamond cutting of glass soda-lime. Chin J Mech Eng 25:1224–1230CrossRefGoogle Scholar
  16. 16.
    Yan J, Syoji K, Tamaki J (2003) Some observations on the wear of diamond tools in ultra-precision cutting of single-crystal silicon. Wear 255:1380–1387CrossRefGoogle Scholar
  17. 17.
    Zhang Z, Yan J, Kuriyagawa T (2011) Study on tool wear characteristics in diamond turning of reaction-bonded silicon carbide. Int J Adv Manuf Technol 57:117–125CrossRefGoogle Scholar
  18. 18.
    Li XP, He T, Rahman M (2005) Tool wear characteristics and their effects on nanoscale ductile mode cutting of silicon wafer. Wear 259:1207–1214CrossRefGoogle Scholar
  19. 19.
    Wada R, Kodama H, Nakamura K, Mizutani Y, Shimura Y, Takenaka N (1980) Wear characteristics of single crystal diamond tool. CIRP Ann Manuf Technol 29:47–52CrossRefGoogle Scholar
  20. 20.
    Oomen JM, Eisses J (1992) Wear of monocrystalline diamond tools during ultraprecision machining of nonferrous metals. Precis Eng 14:206–218CrossRefGoogle Scholar
  21. 21.
    Song YC, Nezu K, Park CH, Moriwaki T (2009) Tool wear control in single-crystal diamond cutting of steel by using the ultra-intermittent cutting method. Int J Mach Tool Manu 49:339–343CrossRefGoogle Scholar
  22. 22.
    Yin ZQ, TO S, Lee WB (2009) Wear characteristics of diamond tool in ultraprecision raster milling. Int J Adv Manuf Technol 44:638–647CrossRefGoogle Scholar
  23. 23.
    Zhang G, TO S, Zhang S (2016) Relationships of tool wear characteristics to cutting mechanics, chip formation, and surface quality in ultra-precision fly cutting. Int J Adv Manuf Technol 83:133–144CrossRefGoogle Scholar
  24. 24.
    Zhang G, TO S, Zhang S (2016) Evaluation for tool flank wear and its influences on surface roughness in ultra-precision fly cutting. Int J Mech Sci 118:125–134CrossRefGoogle Scholar
  25. 25.
    Zhang G, TO S, Xiao G (2014) The relation between chip morphology and tool wear in ultra-precision raster milling. Int J Mach Tools Manuf 80:11–17CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control EngineeringShenzhen UniversityShenzhenChina
  2. 2.State Key Laboratory of Ultra-Precision Machining Technology, Department of Industrial and Systems EngineeringThe Hong Kong Polytechnic UniversityHong KongChina

Personalised recommendations