Abstract
Summary The paper deals with the life, the wear of single crystal diamond tools and their effects on the micro-roughness and the residual stress of the surface layers, under various machining conditions. Three kinds of diamond tools, having different nose radii, were used for mirror finishing of aluminum alloy workpieces. Cutting tests were carried out untill the cutting distance of a tool reached to 900Km. Despite of tool wear, the roughness of diamond-turned surface remains almost constant due to the burnishing effects. The micro-roughnesses are more or less varied by the feed rate and the nose radius of the cutting edge. Also the micro-roughness relate closely with the thrust forces. X-ray diffraction analysis was also conducted to determine the residual stress for each process. In the mirror finishing process, compressive stress of about 60 MPa remains on the surface layers. The thickness of the work-affected layer is merely on the order of submicrometers.
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