Skip to main content
SpringerLink
Log in

Temperature and force measurements in single diamond scratch tests

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Analysis of the highest temperature in the machining processes, namely the flash temperature, helps to understand the physics of the process, to improve cutting tool geometry, and to achieve high performance machining. In the present work, the interaction between cutting grain and workpiece material in grinding process is analyzed. Single diamonds are considered for machining, which operates in comparison to other measurements in the range of grinding speed. The highest temperature in the grain-material interaction and cutting forces are measured. In order to measure the flash temperature, an innovative method to measure and analyze the temperature through the diamond grain in the cutting zone by a two-color pyrometer is proposed. Furthermore, cutting forces are measured simultaneously. In order to measure the temperature in the cutting zone, an accurate connection between diamond and pyrometer fiber is required. Thus, the diamond tool holders are manufactured by electrical discharge machining (EDM) milling in deionized water. A 0.5-mm-diameter hole is drilled in each holder to connect the diamond precisely to the pyrometer fiber. Machining processes are performed with 30 μm depth of cut, cutting length of 20 mm, and cutting speed of 65 m/s on Ti6Al4V. The cutting tool is fixed, and the shape of the rotating workpiece is optimized. The diamond holder with the specific shape is designed and manufactured. Quasi-static, dynamic, modal, and harmonic response analyses are performed in order to reduce vibrations and chattering. The measured flash temperature is 1380 °C and cutting normal, tangential, and axial forces are measured.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Sutter G, Ranc N (2010) Flash temperature measurement during dry friction process at high sliding speed. Wear 268(11–12):1237–1242

    Article  Google Scholar 

  2. Childs PRN Practical temperature measurement. 2001. Oxford: Oxford : Butterworth-Heinemann

  3. Mller B, Renz U (2001) Development of a fast fiber-optic two-color pyrometer for the temperature measurement of surfaces with varying emissivities. Rev Sci Instrum 72(8):3366–3374

    Article  Google Scholar 

  4. Kops L, Shaw MC (1982) Thermal radiation in surface grinding. CIRP Ann 31(1):211–214

    Article  Google Scholar 

  5. Akbari M, Buhl S, Leinenbach C, Wegener K (2016) A new value for Johnson Cook damage limit criterion in machining with large negative rake angle as basis for understanding of grinding. J Mater Process Technol 234:58–71

    Article  Google Scholar 

  6. Ueda T, Hosokawa A, Yamamoto A (1985) Studies on temperature of abrasive grains in grinding—application of infrared radiation pyrometer. CODEN: JEFIA8 107(2):127–133

    Google Scholar 

  7. Ueda T, Hosokawa A, Yamamoto A (1986) Measurement of grinding temperature using infrared radiation pyrometer with optical fiber. CODEN: JEFIA8 108(4):247–251

    Google Scholar 

  8. Hebber RR, Chandrasekaar S, Farris TN (1992) Ceramic grinding temperatures. J Am Ceram Soc 75(10):2742–2748

    Article  Google Scholar 

  9. Chandrasekar S, Farris TN, Bhushan B (1990) Grinding temperatures for magnetic ceramics and steel. JOTRE9: J TRIBOL-T ASME 112(3):535–541

    Google Scholar 

  10. Xu X, Malkin S (2001) Comparison of methods to measure grinding temperatures. J MANUF SCI E-T ASME 123(2):191–195

    Article  Google Scholar 

  11. Malkin S, Guo C (2008) Grinding technology : theory and application of machining with abrasives. 2nd ed. ed. Industrial Press, New York

    Google Scholar 

  12. Blok H (1963) The flash temperature concept. Wear 6(6):483–494

    Article  Google Scholar 

  13. Tapetado A, García E., Díaz-Álvarez J, Miguélez MH, and Vazquez C (2016) Optical-fiber pyrometer positioning accuracy analysis. in Sixth European Workshop on Optical Fibre Sensors (EWOFS'2016). SPIE.p. 4

  14. Vázquez C, Pérez-Prieto S, López-Cardona J, Tapetado A, Blanco E, Moreno-López J, Montero D, Lallana P (2018) Fiber-optic pyrometer with optically powered switch for temperature measurements. Sensors 18(2):483

    Article  Google Scholar 

  15. Tala M, Bertrand G, Hassan P (2017) Temperature measurement of flat glass edge during grinding and effect of wheel and workpiece speeds. MeScT 28(6):065008

    Google Scholar 

  16. Liu D, Wang G, Nie Z, Rong Y (2016) An in-situ infrared temperature-measurement method with back focusing on surface for creep-feed grinding. Measurement 94:645–652

    Article  Google Scholar 

  17. Di Ilio A, Paoletti A, Sfarra S (2018) Monitoring of MMCs grinding process by means of IR thermography. Procedia Manuf 19:95–102

    Article  Google Scholar 

  18. Ueda T, Sato M, Sugita T, Nakayama K (1995) Thermal behaviour of cutting grain in grinding. CIRP Ann-Manuf Technol 44(1):325–328

    Article  Google Scholar 

  19. Lin J (1995) Inverse estimation of the tool-work interface temperature in end milling. Int J Mach Tools Manuf 35(5):751–760

    Article  Google Scholar 

  20. Ueda T, Sato M, Nakayama K (1998) The temperature of a single crystal diamond tool in turning. CIRP Ann 47(1):41–44

    Article  Google Scholar 

  21. Huo D (2013) Micro-cutting: fundamentals and applications. John Wiley & Sons

  22. Coates PB (1981) Multi-wavelength pyrometry. Metrologia 17(3):103–109

    Article  Google Scholar 

  23. Khan MA, Allemand C, Eagar TW (1991) Noncontact temperature measurement. I. Interpolation based techniques. RScI 62(2):392–402

    Google Scholar 

  24. Davies MA, Ueda T, M'Saoubi R, Mullany B, Cooke AL (2007) On the measurement of temperature in material removal processes. CIRP Ann-Manuf Technol 56(2):581–604

    Article  Google Scholar 

  25. Touloukian YS and DeWitt DP, Thermal radiative properties—metallic elements and alloys. 1970

    Book  Google Scholar 

  26. Viacheslav Lel, Fire-3, Faseroptisches Zwei-Farben Pyrometer, Rwth Aachen University-Wsa, Editor. 2007

  27. Transchel R, Stirnimann J, Blattner M, Bill B, Thiel R, Kuster F, Wegener K (2012) Effective dynamometer for measuring high dynamic process force signals in micro machining operations. Procedia CIRP 1(Supplement C):558–562

    Article  Google Scholar 

  28. Akbari M., Thermomechanical analysis of machining and brazing. 2016: ETH Zürich. 147

  29. Astakhov VP, Geometry of single-point turning tools and drills : fundamentals and practical applications. Springer series in advanced manufacturing. 2010: London : Springer 565

  30. ANSYS Inc, Mechanical Application Documentation, Release 18.2. 2018, Canonsburg, PA 15317, USA

  31. Jimin H and Zhi-Fang F., Modal analysis, ed. Jimin he and Zhi-fang Fu. 2001, Oxford: Oxford : Butterworth-Heinemann

  32. ANSYS Inc, Theory Reference for the Mechanical APDL and Mechanical Applications, ed. Peter Kohnke. 2009, USA: SAP IP. P. 1226

  33. Tawakoli T, Hadad MJ, Sadeghi MH, Daneshi A, Stöckert S, Rasifard A (2009) An experimental investigation of the effects of workpiece and grinding parameters on minimum quantity lubrication—MQL grinding. Int J Mach Tools Manuf 49(12):924–932

    Article  Google Scholar 

  34. Fedoseev DV, Vnukov SP, Bukhovets VL, Anikin BA (1986) Surface graphitization of diamond at high temperatures. SuCT 28(2):207–214

    Google Scholar 

  35. Yu ZY, Masuzawa T, Fujino M (1998) Micro-EDM for three-dimensional cavities - development of uniform wear method. CIRP Ann Manuf Technol 47(1):169–172

    Article  Google Scholar 

  36. Kliuev M, Boccadoro M, Perez R, Dal Bó W, Stirnimann J, Kuster F, Wegener K (2016) EDM drilling and shaping of cooling holes in Inconel 718 turbine blades. Procedia CIRP 42:322–327

    Article  Google Scholar 

  37. Buhl S, Failure mechanisms of heavily-loaded brazed diamonds. Fertigunstechnik, Diss ETH No 20386. 2012, Duesseldorf, Germany VDI Verlag Gmbh 147

  38. Evans T and James P. A study of the transformation of diamond to graphite. in Proc R Soc Lond A. 1964. The Royal Society.P. 260–269

  39. Seal M (1963) The effect of surface orientation on the graphitization of diamond. Phys Status Solidi B 3(4):658–664

    Article  Google Scholar 

  40. Davies G and Evans T. Graphitization of diamond at zero pressure and at a high pressure. in Proc R Soc Lond A. 1972. The Royal Society.P. 413–427

  41. J. E (1992) Field. Academic Press, The properties of natural and synthetic diamond

    Google Scholar 

  42. Akbari M, Knapp W, Wegener K (2016) Comparison of transparent objects metrology through diamond cutting edge radii measurements. CIRP-JMST 13:72–84

    Google Scholar 

  43. Taylor Hobson Ltd, Form Talysurf Series 2, Operator's Handbook, No. K505/9. Taylor/Hobson precision Ltd,: Leicester, England, LE4 9JQ

  44. Weller Tools US, STATION 50/60W 120V WES51, catalog number WES51. 2018

    Google Scholar 

Download references

Acknowledgements

The authors would like to thank MTTRF for their support for 5-axis machining center of Mori-Seiki NMV5000 DCG-MTTRF and support from Fredy Kuster, Marco Boccadoro, Sandro Wigger, Daniel Spescha, Lukas Seeholzer, and Michael Steck.

Author information

Author notes

  1. Mansur Akbari and Mikhail Kliuev contributed equally to this work.

Authors and Affiliations

  1. Inspire AG, ETH Zurich, Technoparkstrasse 1, 8005, Zurich, Switzerland

    Mansur Akbari, Jens Boos & Konrad Wegener

  2. Institute of Machine Tools and Manufacturing, ETH Zurich, Leonhardstrasse 21, 8092, Zurich, Switzerland

    Mikhail Kliuev & Konrad Wegener

Authors
  1. Mansur Akbari
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mikhail Kliuev
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jens Boos
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Konrad Wegener
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Mansur Akbari or Mikhail Kliuev.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Akbari, M., Kliuev, M., Boos, J. et al. Temperature and force measurements in single diamond scratch tests. Int J Adv Manuf Technol 96, 4393–4405 (2018). https://doi.org/10.1007/s00170-018-1930-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-1930-0

Keywords

Search

Navigation