Research On Tool Wear And Surface Quality In Diamond Cutting Of Ferrous Metals

Ferrous metals are wildly used in industrial, aerospace and medical fieldsbecause of their wonderful mechanical properties. Cemented carbide, ceramic andcubic boron nitride materials are used for cutting tools in conventional ferrousmetals cutting. However, these materials are confined due to their mechanicalproperties. It is hard for them to achieve requirement of high precision and in realproduction. While, single point diamond tool is suitable for precision andultra-precision cutting. However, the rate of tool wear is too fast to finish theprocess well in conventional diamond tool cutting of ferrous materials. Therefore, itis significant to research on process technique of diamond cutting ferrous metals, forthe reason that it can help reduce tool wear and enlarge applications of diamond toolin precision cutting.This article has experimental research on single diamond tool cutting of diesteels assisted with ultra-sonic vibration. Based on the Abaqus finite element models,influences of ultra-sonic vibration parameters, cutting parameters, tool geometricparameters on cutting force and cutting temperature in cutting process is studied.Then, this article has compared cutting force and temperature between conventionalcutting and ultra-sonic vibration cutting. It can supply theory guide for machiningexperiments in the real condition.Combined with the results of finite element models, ultra-sonic vibrationcutting experiments have been taken with typical die steels in order to discuss theinfluences of cutting parameters, tool geometric parameters on machined surfaceroughness. Then, this article has chose five widely used die steels and studiedaffects of material components on machined surface roughness. In addition, modlewhich for the reason to except surface quality has been set up. This research cansupply theory basis for developing surface quality.By means of SEM, this article has compared rake face and flank face tool wearbetween conventional cutting and ultra-sonic vibration cutting. And future researchon orthogonal experiment to analyse the impacts of cutting parameters, toolgeometric parameters on tool wear, for the sake of exploring technology which canhelp reduce tool wear have been taken. In addition, this article has set up modle forexcepting tool wear, which can also search for new methord to reduce tool wearwell.