Next Article in Journal
Partition of Primary Shear Plane Heat in Orthogonal Metal Cutting
Previous Article in Journal
Minimisation of Heating Time for Full Hardening in Hot Stamping Using Direct Resistance Heating
Open AccessArticle

Suppression of Polycrystalline Diamond Tool Wear with Mechanochemical Effects in Micromachining of Ferrous Metal

by Yan Jin Lee 1, Yung-Kang Shen 2,3 and Hao Wang 1,*
1
Department of Mechanical Engineering, National University of Singapore, 9 Engineering Drive 1, Singapore 117575, Singapore
2
School of Dental Technology, College of Oral Medicine, Taipei Medical University, Taipei City 110, Taiwan
3
Research Center for Biomedical Devices, Taipei Medical University, Taipei City 110, Taiwan
*
Author to whom correspondence should be addressed.
J. Manuf. Mater. Process. 2020, 4(3), 81; https://doi.org/10.3390/jmmp4030081
Received: 10 July 2020 / Revised: 24 July 2020 / Accepted: 6 August 2020 / Published: 11 August 2020
(This article belongs to the Special Issue Progress in Precision Machining)
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 affirmed 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 μm/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 efficiency. 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. View Full-Text
Keywords: polycrystalline diamond; tribo-chemical tool wear; ultraprecision machining; microcutting; mechanochemical effect; low-magnetic iron polycrystalline diamond; tribo-chemical tool wear; ultraprecision machining; microcutting; mechanochemical effect; low-magnetic iron
Show Figures

Figure 1

MDPI and ACS Style

Lee, Y.J.; Shen, Y.-K.; Wang, H. Suppression of Polycrystalline Diamond Tool Wear with Mechanochemical Effects in Micromachining of Ferrous Metal. J. Manuf. Mater. Process. 2020, 4, 81.

Show more citation formats Show less citations formats
Note that from the first issue of 2016, MDPI journals use article numbers instead of page numbers. See further details here.

Article Access Map by Country/Region

1
Back to TopTop