Detection of orientation-dependent, single-crystal diamond tool edge wear using cutting force sensors, while spin-turning silicon

This paper shows results of an effort to turn brittle materials using a round insert that can be rotated to present a fresh edge to the cutting zone. The rotating cutting tool was originally proposed by Shaw to maintain edge sharpness during heavy lathe turning operations. His approach is applied here, with design enhancements, to precision diamond turning. This work seeks to experimentally determine the benefits of spin-turning infrared materials known to cause rapid wear of single-crystal, synthetic diamond cutting tools. The results explore the specific issues of maintaining satisfactory surface finish over anisotropic workpieces such as single-crystal silicon. This is demonstrated using a stiff and accurate spindle-based tool holder that is instrumented to provide feedback while cutting. (C) 2009 Elsevier Inc. All rights reserved.