Suppression of Polycrystalline Diamond ToolWear with Mechanochemical Effects in Micromachining of Ferrous Metal

Yan Jin Lee, Yung Kang Shen, Hao Wang

Research output: Contribution to journalArticlepeer-review

Abstract

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 affrmed 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-m/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 effciency. 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.

Original languageEnglish
Article number4030081
JournalJournal of Manufacturing and Materials Processing
Volume4
Issue number3
DOIs
Publication statusPublished - Sep 1 2020

Keywords

  • Low-magnetic iron
  • Mechanochemical effect
  • Microcutting
  • Polycrystalline diamond
  • Tribo-chemical tool wear
  • Ultraprecision machining

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering
  • Mechanics of Materials

Fingerprint Dive into the research topics of 'Suppression of Polycrystalline Diamond ToolWear with Mechanochemical Effects in Micromachining of Ferrous Metal'. Together they form a unique fingerprint.

Cite this