Wear Behaviors of PCD Tools in Turning Granite

Abstract:

The performance and wear mechanisms of two types of polycrystalline diamond (PCD) cutting tools (marked as PCD 010 and PCD 030) have been investigated in this paper. Continuous turning of round granite bars has been selected as the test method. The Taylor equation has been developed to describe the tool performance. The experimental results indicate that PCD 010 has a greater thermal wear resistance than PCD 030 at high cutting speeds. Scanning electron microscopy (SEM) was used to evaluate wear mechanisms of PCD tools, our results show that the dominant wear mechanisms for PCD 010 is abrasion wear while that for PCD 030 is inter-granular and cleavage wear.

• Periodical: Advanced Materials Research (Volume 337)
• Pages: 728-734
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.337.728
• Online since: September 2011
• Authors: Rui Zhang, Zi Li Kou, Yun Wei Dou, Shen Zhuo Liu, Hai Kuo Wang, Kai Xue Wang, Ying Chen, Huan Ma, Cheng Liang Liu
• Keywords: Granite Bars, Polycrystalline Diamond (PCD), Taylor Equation, Wear

References

[1] K.Weinert, A consideration of tool wear mechanism when machining metal matrix composite (MMC), Ann. CIRP 42 (1993) 95-98.

DOI: 10.1016/s0007-8506(07)62400-7

[2] J.T. Lin, D. Bhattacharyya, C. Lane,Machinability of a silicon carbide reinforced aluminium metal matrix composite, Wear 181-183 (1995) 883-888.

DOI: 10.1016/0043-1648(95)90211-2

[3] C.A.C. Antonio, J.P. Davim, Optimum cutting conditions in turning of particulate metal matrix composites based on experimental and a generic search model, Composites Part A 33 (2002) 213-219.

DOI: 10.1016/s1359-835x(01)00094-x

[4] M. El-Gallab,M. Sklad, Machining of Al/SiC particulate metal matrix composites Part I: tool performance, J. Mater. Process. Technol. 83 (1998) 151-158.

DOI: 10.1016/s0924-0136(98)00054-5

[5] C.J.E. Andrews, H.Y. Feng, W.M. Lau, Machining of an aluminium/SiC composite using diamond inserts, J. Mater. Process. Technol. 102 (2000) 25-29.

[6] Paulo Davim J. Diamond tool performance in machining metal-matrix composites. J Mater Process Technol. 2002;128:100-5.

[7] Peter J. Heath, Developments in applications of PCD tooling, Journal of Materials Processing Technology 116 (2001) 31-38

DOI: 10.1016/s0924-0136(01)00837-8

[8] X. Ding, W.Y.H. Liew, X.D. Liu, Evaluation of machining performance of MMC with PCBN and PCD tools, Wear 259 (2005) 1225-1234

DOI: 10.1016/j.wear.2005.02.094

[9] J.A. Arsecularatne, L.C. Zhang, C. Montross, Wear and tool life of tungsten carbide, PCBN and PCD cutting tools, International Journal of Machine Tools & Manufacture 46 (2006) 482–491

DOI: 10.1016/j.ijmachtools.2005.07.015

[10] Q.S. Bai, Y.X. Yao , Phillip Bex , G. Zhang ,Study on wear mechanisms and grain effects of PCD tool in machining laminated flooring, International Journal of Refractory Metals & Hard Materials 22 (2004) 111-115

DOI: 10.1016/j.ijrmhm.2004.01.007

[11] J.A. Arsecularatne, Prediction of tool life for restricted contact and grooved tools based on equivalent feed, International Journal of Machine Tools & Manufacture 44 (2004) 1271-1282

DOI: 10.1016/j.ijmachtools.2004.04.022

[12] Y. Kevin Chou, Chris J. Evans, Moshe M. Barash, Experimental investigation on CBN turning of hardened AISI 52100 steel, Journal of Materials Processing Technology 124 (2002) 274-283

DOI: 10.1016/s0924-0136(02)00180-2

[13] J.A. Arsecularatne, L.C. Zhang, C. Montross, Wear and tool life of tungsten carbide, PCBN and PCD cutting tools, International Journal of Machine Tools & Manufacture 46 (2006) 482-491 Fig. 1 Fig. 1 Photographs of a fresh PCD tool: (a) flank face and (b) rake face. Fig. 2 Fig. 2 Photographs of a tool flank face (c–e) and rake face (f–h) at different cutting time (PCD 010, in wet cutting, cutting speed: 150 m/min, feed rate: 0.1 mm/rev, and depth of cut: 0.15 mm). Fig. 3 Fig. 3 Effect of cutting speed on tool life of PCD 010 and PCD 030 on a log–log basis (in wet cutting, cutting speed: 120-200 m/min, feed rate: 0.1 mm/rev, and depth of cut: 0.15 mm) Fig. 4 Fig. 4 Taylor lines for PCD 010 and PCD 030 on granite (cutting speed: 120-200 m/min, feed rate: 0.1 mm/rev, and depth of cut: 0.15 mm) Fig. 5 Fig. 5 SEM of fresh PCD tools: (a) PCD 010, (b) PCD 030. Fig. 6 Fig. 6 SEM of the PCD 010 used to machine granite bar at 120 m/min for a maximum flank wear of 0.5 mm. Fig. 7 Fig. 7 SEM of the PCD 010 used to machine granite bar at 200 m/min for a maximum flank wear of 0.5 mm. Fig. 8 Fig. 8 SEM of the PCD 030 used to machine granite bar at 120 m/min for a maximum flank wear of 0.5 mm. Fig. 9 Fig. 9 SEM of the PCD 030 used to machine granite bar at 200 m/min for a maximum flank wear of 0.5 mm. Table 1 Chemical composition of granite SiO2 Al2O3 K2O Na2O CaO FeO Fe2O3 MgO TiO2 P2O5 MnO 72.04% 14.42% 4.12% 3.69% 1.82% 1.68% 1.22% 0.71% 0.30% 0.12% 0.05% Table 2 Tool geometry Rake angle(°) Relief angle(°) Chamfer angle(°) Chamfer length（mm） Approach angle (°) -5 5 20 0.2 95 Table 3 Process parameters in different machining sets Cutting test Cutting speed (m/min) Feed rate (mm/rev) Depth of cut (mm) 120 ，150 , 180 , 200 0.1 0.15