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Effects of tool wear on surface micro-topography in ultra-precision turning

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Abstract

In ultra-precision turning of large optical components, the surface quality deterioration caused by tool wear has severely restricted the optical performance of these components. To investigate the effects of tool wear on surface micro-topography, this paper conducts an experimental study on the ultra-precision turning of copper. The wear characteristics of the diamond tool and the micro-topography of the ultra-precision turned surface at different cutting distances are discussed and evaluated. The plastic deformation behavior of the workpiece material is investigated at various cutting parameters and tool wear conditions. Furthermore, the power spectral density (PSD) and the diffraction optical characteristics of the machined surface are achieved and analyzed quantitatively. The experimental results show that during diamond turning of copper, the tool wear is mainly characterized by the micro-breakages on the tool edge when the cutting distance is less than 24 km. With the increase of the cutting distance, the micro-breakages gradually develop into the continuous wear land, and the enlarged wear area is attributed to the cumulative cleavage fractures and uniform mechanical wear. Moreover, the increased tool wear can result in more pronounced periodic surface micro-topography and greater height of the material pile up, which will deteriorate the optical performance and enhance the diffraction effect of the ultra-precision turned surface.

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Funding

This work is financially supported by the National Natural Science Foundation of China (Grant No. 51705070), the Science Foundation Ireland (SFI) (No. 15/RP/B3208), the Fundamental Research Funds for the Central Universities (Grant No. N172304037), and the Natural Science Foundation of Hebei Province (Grant No. E2018501038).

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Authors and Affiliations

  1. School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, China

    Dongxu Wu

  2. Centre of Micro/Nano Manufacturing Technology (MNMT-Dublin), University College Dublin, Dublin, Ireland

    Dongxu Wu & Fengzhou Fang

  3. Center for Precision Engineering, School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Bo Wang

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  1. Dongxu Wu
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  2. Bo Wang
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Correspondence to Dongxu Wu.

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Wu, D., Wang, B. & Fang, F. Effects of tool wear on surface micro-topography in ultra-precision turning. Int J Adv Manuf Technol 102, 4397–4407 (2019). https://doi.org/10.1007/s00170-019-03494-8

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  • DOI: https://doi.org/10.1007/s00170-019-03494-8

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