Ultrasonic tooling system design and development for single point diamond turning (SPDT) of ferrous metals

  • Rimvydas Gaidys
  • Olaf Dambon
  • Vytautas Ostasevicius
  • Clemens Dicke
  • Birute Narijauskaite


In ultra-precision diamond turning, work pieces with a surface roughness of R a < 5 nm and a form accuracy of <250 nm can be machined. Materials such as alumina, copper, electroless nickel and some plastics are mainly used in this process. In conventional ultra-precision diamond turning, it is not possible to machine ferrous metals such as hardened steel. A chemical reaction between carbon of the diamond and iron of the steel takes place and increases the tool wear significantly. The method of adding ultrasonic vibrations to the cutting process was developed to reduce the contact time between tool and work piece. This method leads to a significant reduction of the chemical process and thus enables the machining of ferrous materials with diamond tools. For the realization of this method, an ultrasonic tool holder was designed and a prototype of this tool holder was elaborated. Based on a longitudinal excited transducer, a longitudinal wave is transformed through a flexural sonotrode into a transversal wave. The aim of the new development was to reach a higher operating frequency of 100 kHz and minimize disadvantageous features related to weight and geometry of such devices.


Ultra-precision single point diamond turning Ultrasonic tool holder design Harmonic response Transient analysis 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. 1.
    Grazeviciute J, Skiedraite I, Ostasevicius V, Jurenas V, Bubulis A (2006) Ultrasound application in turning process. Proc Int Conf Vibroeng 2006 152-154Google Scholar
  2. 2.
    Ostasevicius V, Gaidys R, Dauksevicius R, Mikuckyte S (2013) Study of vibration milling for improving surface finish of difficult-to-cut materials. Stroj Vestn-J Mech E 59(6):351–357CrossRefGoogle Scholar
  3. 3.
    Moriwaki T, Shamoto E (1991) Ultraprecision diamond turning of stainless steel by applying ultrasonic vibration. Ann CIRP 40(1):559–562CrossRefGoogle Scholar
  4. 4.
    Klocke F, Dambon O, Bulla B, Heselhaus M (2008) Ultrasonic assisted turning of hardened steel with mono-crystalline diamond. Proc Ann Meet Am Soc Precis Eng 2008: 165–169Google Scholar
  5. 5.
    Klocke F, Dambon O, Bulla B (2011) Tooling system for diamond turning of hardened steel moulds with aspheric or no rotational symmetrical geometries. Euspen Conf. Proc.Google Scholar
  6. 6.
    Zhang J, Suzuki N, Wang Y, Shamoto E (2014) Fundamental investigation of ultra-precision ductile machining of tungsten carbide by applying elliptical vibration cutting with single crystal diamond. Int J Mater Process Technol 214(11):2644–2659CrossRefGoogle Scholar
  7. 7.
    Kim GD, Loh BG (2007) An ultrasonic elliptical vibration cutting device for micro V-groove machining: kinematical analysis and micro V-groove machining characteristics. Int J Mater Proc Technol 190:181–188CrossRefGoogle Scholar
  8. 8.
    Lee J, Lee D, Jung Y, Chung W (2002) A study on micro-grooving characteristics of planar light wave circuit and glass using ultrasonic vibration cutting. J Mater Proc Technol 130–131:396–400CrossRefGoogle Scholar
  9. 9.
    Goel S, Luo X, Comley P, Reuben RL, Cox A (2013) Brittle–ductile transition during diamond turning of single crystal silicon carbide. Int J Mach Tools Manuf 65:15–21CrossRefGoogle Scholar
  10. 10.
    Ravindra D, John Patten J (2011) Ductile regime single point diamond turning of quartz resulting in an improved and damage free surface. Mach Sc and Tech 15:357–375CrossRefGoogle Scholar
  11. 11.
    Jasinevicius RG, Duduch JG, Montanari L, Pizani PS (2012) Dependence of brittle-to-ductile transition on crystallographic direction in diamond turning of single-crystal silicon. Proc Inst Mec Eng Part B: J Eng Manuf 226:445–458CrossRefGoogle Scholar
  12. 12.
    Yan J, Zhang Z, Kuriyagawa T (2009) Mechanism for material removal in diamond turning of reaction-bonded silicon carbide. IntJ Mach Tools Manuf 49(5):366–374CrossRefGoogle Scholar
  13. 13.
    Wang M, Wang W, Lu Z (2012) Anisotropy of machined surfaces involved in the ultra-precision turning of single-crystal silicon—a simulation and experimental study. Int J Adv Manuf Techn 60(5–8):473–485Google Scholar
  14. 14.
    Tanaka H, Shimada S, Ikawa N (2004) Brittle-ductile transition in monocrystalline silicon analysed by molecular dynamics simulation. Proc Inst Mech Eng Part C J Mech Eng Sc 218(6):583–590CrossRefGoogle Scholar
  15. 15.
    Goel S, Rashid WB, Luo X, Agrawal A, Jain VK (2014) A theoretical assessment of surface defect machining and hot machining of nano crystalline silicon carbide. J Manuf Sci Eng 136(2):12CrossRefGoogle Scholar
  16. 16.
    Arif M, Xinquan Z, Rahman M, Kumar S (2013) A predictive model of the critical undeformed chip thickness for ductile–brittle transition in nano-machining of brittle materials. Int J Mach Tools Manuf 64:114–122CrossRefGoogle Scholar
  17. 17.
    Patten JA, Jacob J (2008) Comparison between numerical simulations and experiments for single-point diamond turning of single-crystal silicon carbide. J Manuf Proc 10:28–33CrossRefGoogle Scholar
  18. 18.
    Levitas VI, Ma Y, Selvi E, Wu J, Patten JA (2012) High-density amorphous phase of silicon carbide obtained under large plastic shear and high pressure. Amer Phys Soc Phys Rev B 85:054114CrossRefGoogle Scholar
  19. 19.
    Szlufarska I, Ramesh KT, Warner DH (2013) Simulating mechanical behaviour of ceramics under extreme conditions. Ann Rev Mater Res 43:131–156CrossRefGoogle Scholar
  20. 20.
    Zhou M, Wang XJ, Ngoi BKA, Gan JGK (2002) Brittle–ductile transition in the diamond cutting of glasses with the aid of ultrasonic vibration. J Mater Process Technol 121(2–3):243–251CrossRefGoogle Scholar
  21. 21.
    Ikeda T (1990) Fundamentals of piezoelectricity. Oxford University Press, Oxford, New York, TokyoGoogle Scholar
  22. 22.
    Lerch R (1988) Simulation of piezoelectric devices by two and three dimensional finite elements. IEEE Trans Ultrason Ferroelectr Freq Control 37:643–654Google Scholar
  23. 23.
    Ravindra V, Ramakrishna R (2015) Vibration analysis of tapered beam. Int J Emerg Eng Res Technol 3(5):26–32Google Scholar

Copyright information

© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  • Rimvydas Gaidys
    • 1
  • Olaf Dambon
    • 2
  • Vytautas Ostasevicius
    • 1
  • Clemens Dicke
    • 3
  • Birute Narijauskaite
    • 4
  1. 1.Institute of MechatronicsKaunas University of TechnologyKaunasLithuania
  2. 2.Fraunhofer Institute of Production Technology IPTAachenGermany
  3. 3.son-x GmbHAachenGermany
  4. 4.Faculty of Mathematics and Natural SciencesKaunas University of TechnologyKaunasLithuania

Personalised recommendations