Wear characteristics of the pointed diamond tool in ultraprecision and micro cutting of Al 6061 V-grooves

Pointed diamond tool has been widely used in ultraprecision manufacturing of V-grooves. This article provides a wear law and wear characteristics of pointed diamond tool during V-grooves machining with the consideration of the cutting stress and the strength of diamond, which could be used to estimate the tool wear state and control the V-grooves machining quality. In this research, the model of cutting stress distribution and cutting force in V-grooves machining are established, which indicate that the maximum normal stress is independent on the cutting depth. Then, the tool tip fracture condition and cutting edge wear law of pointed diamond tool are further explored. The obtained law and experiments results shows that the tool wear is reflected in the cutting edge radius increasing while the wear rate is high at the beginning and then decreases gradually. Besides, the wear characteristic of the tool tip is different from the side cutting edge due to the diamond strength anisotropy. Raman spectra analysis indicates the wear mechanism of the tool is mechanical friction wear in machining of Al 6061 V-grooves.

Automated summary

This research discusses the wear characteristics and wear law of pointed diamond tools in V-groove processing, as well as the model of cutting stress distribution and cutting force. The wear of pointed diamond tools is reflected in the increase of cutting edge radius, with a high wear rate initially that gradually decreases.