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Evaluation of milling performance of 50-μm D-shaped carbide tool, polycrystalline diamond-coated carbide tool, and polycrystalline diamond tool

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Abstract

Tool sizes and material properties significantly influence the surface quality of micro grooves and the life of the milling tool in micro milling. Thus, expanding the application range of micro-milling tool sizes and exploring the milling performance of different materials are crucial for high-precision milling. In this study, the experimental research on in situ preparation and in situ milling was conducted using a self-developed high-precision combination machine tool. The preparation of D-shaped micro-milling tools with a diameter of 50 μm class was realized using a wire-cutting electrical discharge grinding technology. The performances of carbide, polycrystalline diamond (PCD)-coated carbide, and PCD tools during the micro-milling process of brass were investigated in terms of tool wear and workpiece surface finish. The results showed that the PCD micro-milling tool had the slightest wear, effectively inhabited burr generation, and had stable side wall and groove bottom processing capabilities compared with uncoated and coated PCD carbide micro-milling tools. In addition, the surface roughness of the PCD micro-milling tool was 41.9% lower than that of the carbide micro-milling tool, and high-precision machining with minimum roughness of 32.37 nm was realized. PCD micro-milling tool had excellent milling properties, which significantly prolonged tool life and improved machining quality and accuracy.

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Acknowledgements

We thank Yongbin Zhang for providing the experimental equipment and its technical assistance.

Funding

This work was supported by the National Natural Science Foundation of China (51475310).

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Authors and Affiliations

  1. College of Mechanical Engineering, University of Shanghai for Science and Technology, Shanghai, 200093, China

    Jin Xin Jiang, Chen Jiang, Rui Gao & Yu Hao

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  1. Jin Xin Jiang
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  2. Chen Jiang
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by [Jiang Chen], [Rui Gao], [Hao Yu]. The first draft of the manuscript was written by [Jiang Jinxin] and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Chen Jiang.

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Jiang, J.X., Jiang, C., Gao, R. et al. Evaluation of milling performance of 50-μm D-shaped carbide tool, polycrystalline diamond-coated carbide tool, and polycrystalline diamond tool. Int J Adv Manuf Technol 128, 1991–2000 (2023). https://doi.org/10.1007/s00170-023-11929-6

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  • DOI: https://doi.org/10.1007/s00170-023-11929-6

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