Suppression of Polycrystalline Diamond Tool Wear with Mechanochemical Effects in Micromachining of Ferrous Metal

Journal of Manufacturing and Materials Processing

YanJin Lee¹  Hao Wang¹  Yung-Kang Shen² 

[1] Department of Mechanical Engineering, National University of Singapore, 9 Engineering Drive 1, Singapore 117575, Singapore;School of Dental Technology, College of Oral Medicine, Taipei Medical University, Taipei City 110, Taiwan;

关键词: polycrystalline diamond;    tribo-chemical tool wear;    ultraprecision machining;    microcutting;    mechanochemical effect;    low-magnetic iron;   

DOI  :  10.3390/jmmp4030081

来源: DOAJ

【 摘 要 】

A mechanochemical effect is investigated to reduce diamond tool wear by means of applying a surfactant to low-carbon magnetic iron during diamond turning. Orthogonal microcutting demonstrates the manifestation of the mechanochemical effect through the reduction of cutting forces by 30%, which supports the notion of lower cutting temperatures for reduced tribo-chemical wear. This is affirmed by the reduction in tool flank wear by up to 56% with the mechanochemical effect during diamond turning. While wear suppression increases by 9.4–16.15% with feeds from 5–20 μm/rev, it is not proportional to the reduction in cutting forces (31–39.8%), which suggests that the reduction in cutting energy does not directly correspond with the reduction in heat energy to sustain tribo-chemical tool wear. The strain localization during chip formation is proposed to serve as a heat source that hinders the wear mitigation efficiency. Finite element simulations demonstrate the heat generation during strain localization under the mechanochemical effect, which counteracts the reduced heat conversion from the plastic deformation and the transfer from tool–chip contact. Hence, this paper demonstrates the effectiveness of the mechanochemical method and its ability to reduce tool wear, but also establishes its limitations due to its inherent nature for heat generation.

【 授权许可】

Unknown