Research on Tool Wear of PCD Micro End Mill in Machining of ZrO₂ Ceramics

Abstract:

This paper presents a study on the tool wear of micro PCD end mill when machining ZrO₂ ceramics. The cutting tool used was a self-designed PCD micro end mill with 1 mm in diameter and single flute. Experiments were conducted on a self-developed micro-milling machine tool. The tool wear characters and progress during the groove milling has been observed. The cutting force and machining accuracy of the grooves also have been studied. Based on the results, it is found that tool wear is mainly on the bottom surface; the cutting force increases with the progress of tool wear; tool wear also affect the width of machined grooves due to the decrease of effective tool diameter.

• Periodical: Materials Science Forum (Volumes 800-801)
• Pages: 20-25
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.800-801.20
• Online since: July 2014
• Authors: Shu Long Wang*, Liang Li, Ning He, Rong Bian, Zhong Bo Zhan, Jing Yu Liu
• Keywords: Ceramic, Micro Milling, PCD Tools, Tool Wear, Zro₂

References

[1] Everitt P., Doggett I, Advanced Ceramics in demands, CeramicIndustry Report, (2009), 13-16.

[2] Eleonora Ferraris, Tom Mestrom, RongBian, Machinability investigation on high speed hard turning of ZrO2 withPCD tools, Procedia CIRP, 1 (2012), 500-505.

DOI: 10.1016/j.procir.2012.04.089

[3] Ferraris E, Reynaerts D, Lauwers B, Micro-EDM process investigation and comparison performance of Al3O2 and ZrO2 based ceramic composites. CIRP Annals - Manufacturing Technology, (2011), 60: 235-238.

DOI: 10.1016/j.cirp.2011.03.131

[4] Hongtao Li, Xinmin Lai, Chengfeng Li, Modelling and experimental analysis ofthe effects of tool wear, minimum chipthickness and micro tool geometry on thesurface roughness in micro-end-milling, J. Micromech. Microeng, 18(2008).

DOI: 10.1088/0960-1317/18/2/025006

[5] Bifano TG, Dow TA, Scattergood RO. Ductile-regime grinding – a newtechnology for machining brittle materials. Journal of Engineering for Industry-Transactions of the Asme, (1991), 113: 184–9.

DOI: 10.1115/1.2899676

[6] Dornfeld D, Min S, Takeuchi Y., Recent advances in mechanical micromachining, CIRP Annals – Manufacturing Technology, (2006), 55: 745-68.

DOI: 10.1016/j.cirp.2006.10.006

[7] RongBian, EleonoraFerrarisb, Ning He, Process investigation on meso-scale hard milling of ZrO2by diamond coated tools, Precision Engineering, (2013), 38: 82-91.

DOI: 10.1016/j.precisioneng.2013.07.007

[8] Cheng X, Wang ZG, NakamotoK, Design and development of a micro polycrystalline diamond ball end mill for micro/nano freeform machining of hard and brittle materials, J MicromechMicroeng, (2009)19.

DOI: 10.1088/0960-1317/19/11/115022

[9] Cheng X, Nakamoto K, Sugai M, Development of ultra-precision machining system with unique wire EDM tool fabrication system for micro/nano-machining. Cirp Ann-ManufTechn, (2008), 57: 415-420.

DOI: 10.1016/j.cirp.2008.03.137

[10] Li P, Micromilling of hardened tool steels, PhD Thesis, TeschnischeUniversiteit Delft, (2009).

[11] Liu X, DeVor RE, Kapoor SG, Ehmann KF, The mechanicsof machining at the microscale: assessment of the current state ofthe science. J ManufSciEng, (2004), 126: 666-678.

DOI: 10.1115/1.1813469