Analysis of Tool Wear Behavior of Single Crystal Diamond Based on FEM Simulation in Micro Turning

Abstract

Micro turning test was performed on nickel plated roll die using ultra precision lathe and lenticular shape single crystal diamond (SCD) tools. For the test, fresh tools were used for each experiment to observe tool wear evolution at the cutting distances. Finite element method (FEM) simulation based on Lagrangian method was also used to calculate contact stress on the cutting surface during the machining process. For the tool wear measurement, scanning electron microscope (SEM) and 3D Nano View, which can provide surface topography of the tools, were used. In addition, Kistler dynamometer was utilized for cutting force measurement. From the experimental result, it was found that a dominant wear mechanism was abrasion due to high contact stresses on the cutting tool surface. And it was also observed that high cutting speed caused high wear rate but slighlty reduced the cutting forces.