Research On Precision Diamond Cutting Of Ferrous Metals

Ferrous metals are wildly used in various industrial areas for their good performances. The request for surface quality and machining precision goes higher and higher in such fields as mechanical, electronic, astronautic, martial engineering. And the diamond tool is recognized as the perfect tool for precision and ultra-precision cutting. But in conventional conditions, the diamond tool is worn so quickly that diamond tool can't be applied in precision and ultra-precision cutting of ferrous metals. There are some precision parts with complex shape used in practical production, and presently grinding and polishing process are still applied with low efficiency and high cost. The research of diamond tool wear machining ferrous metals and discussion of technological methods to decrease tool wear are significant to expand the application area of diamond precision and ultra-precision cutting.The project accomplishes the experimental research of diamond tool wear cutting ferrous metals and precision cutting assisted with ultrasonic vibration. Firstly, four kinds of stainless steels with different stuffs are selected, with which wear experiments of diamond tools in conventional cutting are executed. By micro-appearance test and analysis of rake and flank faces of diamond tools, the wear rule of diamond tools in conventional cutting of stainless steels with different stuffs are analyzed. Secondly, hardness of the same kind stainless steel is changed from the point of material mechanics property. Wear experiments of diamond tools in conventional cutting are executed with stainless steels with five kinds of different hardness, and the influence of the change of hardness is researched.The special jig for fixing the ultrasonic vibration cutting system on the high-precision machines is designed and machined to complete the experiment of diamond cutting assisted with ultrasonic vibration, which will make the system operate stably and ensure the micro-adjust of tool nose to meet demands of the experiment.Then, diamond tool cutting experiments assisted with ultrasonic vibration are executed with four different kinds of stainless steels and the same stainless steels with five different hardness. The special process effects of ultrasonic vibration cutting are researched, such as controlling the diamond tool wear, decreasing the cutting force, improving the machined surface quality. Also, the influences of some cutting process parameters on diamond tool wear and machined surface quality are analyzed, such as feed rate, nominal depth of cut, vibration amplitude.The results of research indicate that diamond tool cutting of ferrous metals assisted with ultrasonic vibration controls the diamond tool wear, decreases the cutting force and improves the machined surface quality.