Diamond Machining of Steel Molds for Optical Applications

Abstract:

Article Preview

As is well known, excessive chemical tool wear occurs when steel alloys are machined with monocrystalline diamond tools prevents many important applications. In order to reduce this catastrophic tool wear, certain process modifications have been proposed in the literature, e.g. cryogenic cutting and elliptical vibration cutting. Another approach for realizing precision machining of steel is coating the diamond with a TiN layer or using ceramic tools. However, only elliptical vibration cutting has proven to be ready for industrial use, but a large amount of auxiliary equipment is needed. The basic idea of the new approach is to avoid chemical reactions between the carbon of the diamond tool and the iron of the substrate by establishing a chemical bond between the iron and other chemical elements in the workpiece's subsurface layer. Using a custom-made thermo-chemical process for altering the chemical composition of the boundary layer of the workpiece the diamond tool wear can be reduced by more than two orders of magnitude. The surface roughness obtained in single point diamond turning of carbon steel was approximately 10 nm Ra and 6 nm Ra for raster milling processes.

Info:

Periodical:

Key Engineering Materials (Volumes 364-366)

Edited by:

Guo Fan JIN, Wing Bun LEE, Chi Fai CHEUNG and Suet TO

Pages:

701-706

Citation:

E. Brinksmeier and R. Gläbe, "Diamond Machining of Steel Molds for Optical Applications", Key Engineering Materials, Vols. 364-366, pp. 701-706, 2008

Online since:

December 2007

Export:

Price:

$38.00

[1] Evans, C.J.; Paul, E.; Mangamelli, A.; Mc Glauflin, M.L.: Chemical aspects of tool wear in single point diamond turning. Prec. Eng. 18(1996)1; p.4.

DOI: https://doi.org/10.1016/0141-6359(95)00019-4

[2] Shimada, S., Tanaka, H., Higuchi, M., Yamaguchi, T., Honda, S., Obata, K.: Thermo-Chemical Wear Mechanism of Diamond Tool in Machining of Ferrous Metals. Annals of the CIRP 53/1 (2004), p.57.

DOI: https://doi.org/10.1016/s0007-8506(07)60644-1

[3] Li, J.: Wear of Single Point Diamond Tool Turning Steel. ASPE Annual Meeting, Atlanta (1988).

[4] Evans, C.: Cryogenic Diamond Turning of Stainless Steel. Annals of the CIRP, Vol. 40, 1 (1991); p.571.

DOI: https://doi.org/10.1016/s0007-8506(07)62056-3

[5] Casstevens J.: Diamond Turning of Steel in Carbon Saturated Atmospheres. Precision Engineering 5(1983)1; p.9.

DOI: https://doi.org/10.1016/0141-6359(83)90063-6

[6] Moriwaki, T.; Shamoto, E.: Ultraprecision Diamond Turning of Stainless Steel by Applying Ultrasonic Vibration. Annals of the CIRP, 40(1991)1; p.559.

DOI: https://doi.org/10.1016/s0007-8506(07)62053-8

[7] Moriwaki, T.; Shamoto, E.: Ultraprecision Diamond Cutting of Hardened Steel by Applying Elliptical Vibration Cutting. Annals of the CIRP, 48(1999)1; p.441.

DOI: https://doi.org/10.1016/s0007-8506(07)63222-3

[8] Klocke, F.; Rübenach O.: Ultrasonic Assisted Diamond Turning of Steel and Glass. Proc. of the Intern. Sem. on Prec. Eng. and Micro Tech., Aachen July 19th /20th (2000); p.179.

[9] Knuefermann, M.; Read, R.; Nunn, R.; Clark, I.; Fleming, A.: Ultrapräzisionsbearbeitung gehärteter Stahlbauteile mit Amborite DBN45. IDR; 34(2000)3; p.222.

[10] Brinksmeier, E.; Gläbe, R.: Elliptical Vibration Cutting of Steel with Diamond Tools. ASPE Annual Meeting (1999) p.163.

[11] Grathwohl, G.; Kunz, M.; Godlinski, D.: Development of ceramics micro tools for Precision maching. Proc. of the 1st International euspen Conference (1999) Bremen, Germany; p.298.