Papers by Keyword: Ductile Cutting

Abstract: This study deals with the effect of tool–surface inclination on cutting forces in ball end milling .Since glass undergoes almost no elastic deformation, the shape of the cutter in glass machining has a larger influence on surface finish than that of metal machining. Model of geometry and tilt tool milling process is established. A double helix micro-flute ball end mill made of cemented carbide is used in the groove milling tests with radius 0.5mm at a helix angle of 30°. The rotational axis of the tool is inclined to improve the surface finish. The cutting processes are modeled, and 3-direction cutting forces are measured via three groups of experiments to show the effect of the tool inclination on the machined surface. Several micro grooves, then, are machined with the crack-free surfaces to prove efficiency and surface quality in the milling process.

Abstract: Tool wear reduction is very important in cutting of ultra hard and brittle materials. In this paper, a tool-swinging cutting method was applied to reduce the wear of round-nosed diamond tools in cutting of tungsten carbide (WC). In this method, the geometrical center of the cutting edge was adjusted to be in coincidence with the rotation center of the B-axis table, and thus the cutting point could be changed along the cutting edge by swinging the tool about the B-axis center. Experimental results showed that the width of the flank wear land was greatly reduced compared to that in the conventional cutting. This work can shed light on ultraprecision machining WC parts without or with less need for subsequent polishing process.

Abstract: The service life of a diamond tool in cutting single-crystal silicon is normally very short because of severe tool wear. Therefore, it is important to use a proper coolant in order to restrain tool wear. In this paper, the performances of oil-based and water-based coolants were compared in silicon machining by investigating cutting forces and tool wear geometries. The water-based coolant was found to restrain flank wear more effectively than the oil-based one. The effective tool life using the water-based one was averagely three times longer than that using the oil-based one. The tool wear mechanism might be related to microplasma generated between silicon and diamond during cutting.