High-Precision Cutting Edge Radius Measurement of Single Point Diamond Tools Using an Atomic Force Microscope and a Reverse Cutting Edge Artifact

Kai Zhang,Wei Gao,Hiraku Matsukuma,Yindi Cai,Yuki Shimizu

doi:10.3390/app10144799

Abstract

This paper presents a measurement method for high-precision cutting edge radius of single point diamond tools using an atomic force microscope (AFM) and a reverse cutting edge artifact based on the edge reversal method. Reverse cutting edge artifact is fabricated by indenting a diamond tool into a soft metal workpiece with the bisector of the included angle between the tool’s rake face and clearance face perpendicular to the workpiece surface on a newly designed nanoindentation system. An AFM is applied to measure the topographies of the actual and the reverse diamond tool cutting edges. With the proposed edge reversal method, a cutting edge radius can be accurately evaluated based on two AFM topographies, from which the convolution effect of the AFM tip can be reduced. The accuracy of the measurement of cutting edge radius is significantly influenced by the geometric accuracy of reverse cutting edge artifact in the proposed measurement method. In the nanoindentation system, the system operation is optimized for achieving high-precision control of the indentation depth of reverse cutting edFigurege artifact. The influence of elastic recovery and the AFM cantilever tip radius on the accuracy of cutting edge radius measurement are investigated. Diamond tools with different nose radii are also measured. The reliability and capability of the proposed measurement method for cutting edge radius and the designed nanoindentation system are demonstrated through a series of experiments.

Highlights

Ultra-precision diamond cutting, combining a single point diamond tool with an ultra-precision lathe, has been widely employed for the fabrication of microstructure elements, such as microlens arrays [1], compound eye freeform surfaces [2], and sinusoidal grids [3,4]
We present high-precision cutting edge radius measurements of single point tools using an atomic force microscope (AFM) and a reverse cutting edge artifact based on the proposed edge reversal method and diamond tools using an AFM and a reverse cutting edge artifact based on the proposed edge reversal the designed nanoindentation system
A series of experiments were performed to investigate the effect of elastic recovery on the reverse cutting edge artifact and the AFM cantilever tip on the measurement accuracy of the cutting edge cutting edge artifact and the AFM cantilever tip on the measurement accuracy of the cutting edge radius as well as to verify the reliability of the proposed edge reversal method and the capability of the radius as well as to verify the reliability of the proposed edge reversal method and the capability of designed nanoindentation system

Summary

Introduction

Ultra-precision diamond cutting, combining a single point diamond tool with an ultra-precision lathe, has been widely employed for the fabrication of microstructure elements, such as microlens arrays [1], compound eye freeform surfaces [2], and sinusoidal grids [3,4]. The achievable machining accuracy of the ultra-precision diamond cutting is significantly affected by the geometry of the diamond tool, including cutting edge contour, cutting edge radius, and tool faces [5,6,7]. In order to achieve a nanometric machining accuracy, it is essential to conduct a quantitative evaluation of the geometry of the diamond tool, especially cutting edge radius, which determines the minimum depth of cut and the surface finish of the machined microstructures [8,9]. Cutting edge radius of a diamond tool is usually required to be within 10 to 100 nm for ultra-precision diamond cutting [10].

Results

Discussion

Conclusion