Abstract
Cemented carbide is currently used for various precise molds and wear resistant parts. However, the machining of cemented carbide still is a difficult challenge due to its superior mechanical properties. In this paper, an experimental study was conducted on direct micro milling of cemented carbide with a polycrystalline diamond (PCD) micro end mill. The cutting force characteristics, surface formation, and tool wear mechanisms were systematically investigated. Experimental results show that cemented carbide can be removed with ductile cutting utilizing the PCD tool with a large tool tip radius. Micro burrs, brittle pits, and cracks are the observed surface damage mechanisms. The tool wear process presents microchipping on the cutting edge and exfoliating on the rake face in the early stage, and then severe abrasive and adhesive wear on the bottom face in the following stage.
Highlights
Mold technology is an important method of mass production in various fields [1,2]
More and more molds are made of cemented carbide instead of steel to fulfill the demands of long mold life and high product quality [3,4,5]
Wojciechowski and Mrozek [14] investigated the dynamics of micro ball end milling with various tool inclination angles and optimized the machining parameters to obtain the minimization of cutting forces, vibrations, and surface roughness
Summary
Mold technology is an important method of mass production in various fields [1,2]. Cemented carbide offers many excellent features such as high hardness, high temperature resistance, and corrosion resistance. IItt uussuuaallllyy ggeenneerraatteess bbrriittttllee ddaammaaggeess ssuucchh aass mmiiccrroo--ppiittss aanndd ccrraacckkss oonn tthhee ssuurrffaaccee mmoorrpphhoollooggyy..HHoowweevveerr,,iifftthheeuunnccuuttcchhiipptthhiicckknneessssiiss ssmmaallll eennoouugghh,, cceemmeenntteedd ccaarrbbiiddee ccaann bbee rreemmoovveedd with ductile cutting and obtain a surface morphology without brittle damages as well.
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