Abstract
A tool manufacturing technique for fabricating a microball endmill with a sharp cutting edge without chipping was developed using nano-polycrystalline diamond (NPD), which is harder than single crystal diamond (SCD), as the tool material. The NPD with a size of 2×3×0.6mm and diamond grain size of several tens of nanometers was roughly formed into a one-flute microball endmill with a radius of 45μm by milling and trimming using a pulsed fiber laser. In addition, wet and dry grinding using a polycrystalline diamond (PCD) disk as a truer were additionally conducted to sharpen the cutting edge without chipping and to adjust the tool radius at 50μm and a clearance angle of 5 degrees. The chipping resistance of the microball endmill was tested by applying the tool to the interrupted cutting of the cemented carbide with a hardness of 13.5GPa Hv. It was verified through the cutting test that the NPD had the potential to fabricate a surface roughness of 20nm Rz without any chipping when the radial depth of cut and the feed rate were set at 0.5μm and 0.5μm/rev, respectively.
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