Investigation on controlling diamond tool edge and wear by ultrasonic vibration

JS Wang and FZ Fang and XD Zhang and D De Simone, APPLIED ACOUSTICS, 176, 107896 (2021).

DOI: 10.1016/j.apacoust.2020.107896

Ultra-precision diamond cutting finds wide applications in various areas such as freeform optics, microstructure arrays and high precision molds. Except for process parameters, machined surface quality is also directly influenced by the state of cutting tool edge. In this paper, a novel method for controlling the tool edge by multi-axis ultrasonic vibration is investigated. Kinematic analysis shows that the effective edge radius can be reduced and varied periodically, which indicates a sharpening effect of the tool. At the first step, numerical simulations including geometrical modelling and molecular dynamics are conducted to lay the theoretical foundation and study the effects of both the process parameters and the material response compared with the traditional ultrasonic vibration assisted cutting. Then, diamond turning, as an experimental approach, is performed to make the final validation of the proposed method based on the analysis of surface roughness, chip formation and tool wear. (C) 2020 Elsevier Ltd. All rights reserved.

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