scholarly journals Theoretical and Experimental Investigations of Tool Tip Vibration in Single Point Diamond Turning of Titanium Alloys

Micromachines ◽  
2019 ◽  
Vol 10 (4) ◽  
pp. 231
Author(s):  
Wai Sze Yip ◽  
Suet To
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Single Point ◽  
Diamond Turning ◽  
Damping Factor ◽  
Vibration System ◽  
Secondary Material ◽  
Material Swelling ◽  
Twin Peak

The material swelling effect in single point diamond turning (SPDT) causes ragged materials on a machined surface which slows down the movements of tool tip vibration, and acts as a simple impacted pendulum system with a damping effect and displays a single twin peak in fast Fourier transform (FFT). Due to the low elastic modulus and low thermal conductivity of titanium alloys, the material swelling effect of titanium alloys in SPDT is much more serious than that of traditional metals. For this reason, the tool tip vibration in SPDT of titanium alloys is expected to be different from previous reports. In this study, apart from the demonstration of the original single twin peak induced from the material swelling effect by the main cutting motion, we reported recently that there exists another twin peak induced by secondary material swelling arising from the movement of tool tip vibration in the SPDT of titanium alloys. The additional twin peak was located at the right side of the original twin peak in FFT, displaying two twin peaks in the frequency domain of cutting force and suggesting the existence of another tool tip vibration system with a new damping factor in the SPDT of titanium alloys. Combining the effects of primary and secondary material swelling, the new dynamic model with the modified damping factor of tool tip vibration system are developed, which surface roughness of the machined titanium alloys in SPDT was predicted in higher accuracy by using the new model. The FFT of cutting force, surface roughness, and surface profile were provided in this article for the experimental validations.

Forecasting of Surface Roughness and Cutting Force in Single Point Diamond Turning for KDP Crystal

2007 ◽  
Vol 339 ◽  
pp. 78-83 ◽  
Author(s):  
Jing He Wang ◽  
Shen Dong ◽  
H.X. Wang ◽  
Ming Jun Chen ◽  
Wen Jun Zong ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
Cutting Force ◽  
Single Point ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Kdp Crystal ◽  
Optimal Cutting Parameters

The method of single point diamond turning is used to machine KDP crystal. A regression analysis is adopted to construct a prediction model for surface roughness and cutting force, which realizes the purposes of pre-machining design, prediction and control of surface roughness and cutting force. The prediction model is utilized to analyze the influences of feed, cutting speed and depth of cut on the surface roughness and cutting force. And the optimal cutting parameters of KDP crystal on such condition are acquired by optimum design. The optimum estimated values of surface roughness and cutting force are 7.369nm and 0.15N, respectively .Using the optimal cutting parameters, the surface roughness Ra, 7.927nm, and cutting force, 0.19N, are obatained.

scholarly journals Single Point Diamond Turning of Calcium Fluoride Optics

2012 ◽  
Vol 516 ◽  
pp. 408-413 ◽  
Author(s):  
Xi Chun Luo ◽  
Ji Ning Sun ◽  
Wen Long Chang ◽  
James M. Ritchie
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Feed Rate ◽  
Calcium Fluoride ◽  
Single Point ◽  
Main Tool ◽  
Cost Effective ◽  
Diamond Turning ◽  
White Spirit

This paper aims to develop a cost-effective diamond turning process to obtain nanosmooth CaF2 optics. Diamond tool wear was also carried out through a number of cutting trials. Three CaF2 specimens (diameter of 50 mm and thickness of 5 mm, crystal orientation of (111)) were diamond turned on an ultra precision lathe (Moore Nanotech 350UPL) by a number of facing cuts. In the cutting trials feed rate varied from 1 μm/rev to 10 μm/rev. White spirit mist was used as the coolant. Cutting forces were measured by a dynamometer (Kistler BA9256). Surface roughness of the CaF2 optics and tool flank wear were measured by a white light interferometer (Zygo Newview 5000) and a scanning electron microscope (FEI Quanta 3D FEG), respectively. It was found that using a feed rate of 1 μm/rev surface roughness Ra of 2 nm could be obtained. When the ratio of the normal cutting force to the tangential cutting force was lower than 1 tool wear would initiate. In diamond turning of calcium fluoride abrasive wear was the main tool wear mechanism. Using white spirit mist as thecoolant could avoid generation of thermal type brittle fracture on the machined CaF2 surfaces.

Analysis of the Swelling Effect in Single-Point Diamond Turning

2011 ◽  
Vol 314-316 ◽  
pp. 984-987
Author(s):  
Qing Liang Zhao ◽  
Jun Yun Chen ◽  
Jian Luo
Keyword(s):  
Surface Roughness ◽  
Material Property ◽  
Single Point ◽  
Diamond Turning ◽  
Surface Generation ◽  
Ductile Material ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Tool Mark ◽  
Material Swelling

The swelling effect is an important factor to affect surface generation in SPDT. Face cutting experiments are conducted for copper, aluminum alloy and electroless nickel phosphorus to analyze the swelling effect including the relationship between it and cutting parameters as well as effect of material property. How the material swelling affects surface roughness is also studied in this paper. The results indicate that the swelling effect is influenced by spindle speed and material property more remarkably when compared to feed rate and depth of cut. In addition, a softer and more ductile material will lead to a stronger material recovery, a lower swelling proportion, a lower tool mark height and a smoother machined surface. The result reveals that the swelling effect must be considered when predicting surface roughness in SPDT

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

Study on the control of surface roughness in single point diamond turning

2012 ◽  
Author(s):  
Honghuai Xu ◽  
Xiangchao Zhang ◽  
Min Xu ◽  
Xufeng Li
Keyword(s):  
Surface Roughness ◽  
Single Point ◽  
Diamond Turning

Study, analysis, and characterization of ultra-precision diamond tools for single-point diamond turning

2020 ◽  
pp. 251659842096533
Author(s):  
RamaGopal V. Sarepaka ◽  
Sivasakthi Balan ◽  
Somaiah Doodala ◽  
Rakesh Singh Panwar ◽  
D. Rajendra Kotaria
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Single Point ◽  
Quality Parameters ◽  
Diamond Turning ◽  
Radius Of Curvature ◽  
Tool Selection ◽  
Diamond Tools ◽  
Surface Irregularities ◽  
Ultra Precision

In multiple applications of advanced instrumentation, single-point diamond turning (SPDT) is a popular and effective process to generate novel surfaces with nanometric surface roughness and sub-micron surface irregularities, albeit at a high cost. In SPDT, precision diamond tooling contributes significantly to the process cost escalation. Hence, for SPDT, it is vital to have an optimal precision diamond tool deployment. In this article, details of comprehensive precision diamond tool selection and tool characterization are discussed. Three makes of selected ultra-precision diamond (UPD) tools and standard diamond tools (of a global make), designated as CFT, are considered for this study. In this tool bench-marking exercise, the fabrication of Cu–Be alloy predesigned precision components (PDPCs) of a critical geometry is selected. UPD and CFT tools are deployed to fabricate (under similar machining-metrology conditions) the PDPCs. These diamond tools are evaluated in terms of the quality parameters (variation in radius of curvature, form error, and surface roughness) of the workpieces. Further, to explore the progressive wear of these tools, multiple machining cycles are conducted on these workpieces, and their quality parameters are analyzed. Thus, the precision diamond tools of three makes are benchmarked against the CFT tool. Based on the final outcome of this analysis, suitable recommendations are provided to precision diamond tool manufacturers to improve their product in terms of performance and optimized costs to meet the ever-growing tooling demands of the SPDT community.

Machinability analysis of quartz during single point diamond turning process based on finite element method: influence of ultrasonic vibration and micro-machining parameters

2020 ◽  
Vol 61 (6) ◽  
pp. 169-178
Author(s):  
Farzad Pashmforoush ◽  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Wear Rate ◽  
Tool Wear ◽  
Cutting Force ◽  
Single Point ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Micro Machining ◽  
Tool Wear Rate

Quartz is one of the difficult-to-machine materials due to its low fracture toughness and high hardness. In this study, the machinability of this material during single point diamond turning (SPDT) was numerically investigated using finite element method (FEM). First of all, the accuracy of the FE model was verified based on the experimental data available in literature. Then, the machinability of quartz was analysed in terms of cutting force, tool/workpiece temperature and tool wear rate. Also, the influence of tool vibration on cutting force and tool wear rate was investigated. Furthermore, an empirical/mathematical model was developed to express the machining outputs as a function of the micro-machining parameters. The obtained results indicate the good performance of FEM in analysing the machinability of quartz during SPDT process.

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