Owing to its ultra-hardness, polycrystalline diamond (PCD) is ideal for the machining of difficult-to-cut materials. According to ISO 3685, flank wear is the main factor that leads to tool rejections. In this study, a new theoretical model was developed by considering both abrasive and adhesive wear in order to investigate the process and mechanism of flank wear of cutting tools made of different PCD materials. The width of flank wear (VB) was calculated by solving the differential equation formulated to describe the rate of flank wear and its relationship with cutting parameters and the properties of tool and workpiece materials. To validate the analytical model, a series of cutting experiments were conducted by turning titanium alloy Ti6Al4V with customized tools made of three types of PCD materials. Morphological characteristics of worn areas were analyzed after each cutting test to investigate the wear process and mechanism. It was found that the wear mechanisms of three different types of PCD tools were different. Calculation outcomes matched experimental results when tools made of CTB002 and CTB010 were used. Obvious deviation was found when the tool made of CTM302 was used due to the occurrence of large-scale fracture of tool tip in the cutting passes.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Nov 2, 2017
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