A novel tool wear suppression method for polycrystalline diamond by applying magnetic field in turning of ferrous materials

Abstract

Ferrous materials are widely used in the mould industry because of their excellent properties. However, ferrous materials are regarded as difficult-to-cut materials for diamond turning due to their affinity for diamond. The resulting catastrophic tool wear leads to high machining costs in ultraprecision turning. The unpaired d-electrons in the workpiece are regarded as the dominant element causing catastrophic diamond wear during the turning. However, an insightful method for unpaired d-electrons in existing assisted machining schemes is still lacking. As a type of diamond tool, polycrystalline diamond (PCD) tools are inexpensive to appropriately carry out wear experiments. Therefore, in this study, a novel assisted method based on a magnetic field (MF) was applied to suppress the PCD tool wear. Experimental results demonstrated that the MF-assisted machining can reduce the flank wear of PCD tools by 30.6%. The spin polarisation of d-electrons by the MF was the dominant mechanism inhibiting the chemical reaction and graphitisation, and thus suppressing the PCD tool wear. Simultaneously, the suppression of machining system vibration by the Lorentz force also had a positive effect on the suppression of the PCD tool wear. The innovative method provides an assisted machining scheme to inhibit the catastrophic wear of PCD tools.

Processing of silicon added Fe-Cr-Co hard magnetic alloy by two stage thermomagnetic treatment technique

“…Magnetic fields with varying intensities have been extensively utilized in several manufacturing processes to control and achieve requisite material characteristics. [21][22][23] In this work, the required magnetic field strength was estimated by initially using integral form theoretical formulae which were then confirmed by Finite Element Analysis (FEA) ANSYS Magnetostatic module, as shown in Figures 4 and 5. ANSYS Workbench 2019 Magnetostatic Module was used for analysis of double coil magnetic field fixture.…”

Optimization of Surface Roughness of Aluminium RSA 443 in Diamond Tool Turning

“…In the case of ferrous materials, diamond tools can wear via a reaction with the substrate that causes the diamond to graphitize. Wear may be partly suppressed by the application of magnetic fields [12]. Investigation has been carried out for the influence of different machining factors on the diamond tool-tip wear during the SPDT of optical grade silicon; thus, the selection and control of cutting parameters must finely controlled [13].…”

A theoretical and experimental investigation into surface generation in ultra-precision diamond milling

“…5,6 During the material removal process, the diamond tool shows excellent performances with good wear resistance, high thermal conductivity, and low friction coefficient to provide surface generation with uniformity and flexibility. 7 Currently, UPDM can be employed into difficult-to-cut materials such as hard and brittle materials and it also offers the highest flexibility for the fabrication of freeform surfaces and micro-structured surfaces. 8,9 Although UPDM exhibits such capabilities, it is sensitive the cutting parameters, 10 material effects, 10 tool geometry, 11 chip formation, 11 and spindle vibration, 12 etc.…”