S1330101 Micro Cutting of Ti Alloy - Tool Wear Evaluation
At a Glance
Section titled “At a Glance”| Metadata | Details |
|---|---|
| Publication Date | 2015-01-01 |
| Journal | The Proceedings of Mechanical Engineering Congress Japan |
| Authors | Hirofumi Suzuki, Mutsumi Okada, Eiji Kato, Masahiro Yamada |
| Institutions | Tohoku University, Chubu University |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Micro Cutting of Ti Alloy (S1330101)
Section titled “Technical Documentation & Analysis: Micro Cutting of Ti Alloy (S1330101)”Executive Summary
Section titled “Executive Summary”This research validates the critical role of Single Crystal Diamond (SCD) and Cubic Boron Nitride (cBN) tools in achieving ultra-precision micro-texturing of Titanium (Ti) alloys, a key process for enhancing the biocompatibility of medical and dental implants.
- Application Focus: Ultra-precision turning of Ti alloy (JIS H 4650 Grade 2) to create micro-textures that promote living body cell fusion for implants.
- Material Validation: Single Crystal Diamond (SCD) and cBN demonstrated superior performance compared to Tungsten Carbide (WC) and CVD-SiC in terms of achievable surface roughness (Rz).
- Tool Wear Performance: cBN exhibited the lowest tool wear volume, followed by SCD, confirming the necessity of superhard materials for high-efficiency Ti micro-machining.
- Surface Quality: SCD and cBN achieved the best surface roughness results, with roughness decreasing significantly as the feed rate increased (up to 10 mm/min).
- 6CCVD Value Proposition: 6CCVD specializes in high-purity, low-defect SCD material, which is the foundational requirement for manufacturing the high-performance micro-cutting tools evaluated in this study.
- Relevance: This work directly supports the growing demand for high-precision diamond components in the biomedical and advanced manufacturing sectors.
Technical Specifications
Section titled “Technical Specifications”The following data points were extracted from the experimental conditions and results, focusing on the Single Crystal Diamond (SCD) tool performance.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Workpiece Material | Ti alloy (JIS H 4650 Grade 2) | N/A | Biocompatible implant material |
| Workpiece Hardness | HV154.2 | N/A | Relatively soft material |
| SCD Tool Radius | 1.02 | mm | Tool geometry |
| SCD Rake Angle | -0.33 | ° | Tool geometry |
| SCD Relief Angle | 13.75 | ° | Tool geometry |
| Depth of Cut | 2 | µm | Micro-cutting parameter |
| Spindle Rotation | 1000 | min-1 | Cutting speed parameter |
| Feed Rate Range | 0.5 to 10 | mm/min | Tested variable |
| Coolant | Kerosene | N/A | Used during cutting |
| Best Surface Roughness (SCD) | Approx. 500 | nm Rz | Achieved at 10 mm/min feed, 128 µm total depth |
| Tool Wear Ratio Ranking (Best to Worst) | cBN < WC < SCD < CVD-SiC | N/A | Based on total depth of cut (Figure 8) |
Key Methodologies
Section titled “Key Methodologies”The experiment utilized ultra-precision turning to evaluate tool wear and surface roughness when micro-cutting Ti alloy disks.
- Machine Setup: Ultraprecision cutting machine (ULG-100D (SH3)) with 1 mm positioning resolution, utilizing linear motor drives for X and Z axes, and an air static pressure bearing for the C-axis (workpiece spindle).
- Workpiece: Flat Ti alloy disks (20 mm diameter x 2 mm thickness) were fixed to a vacuum chuck.
- Tool Materials: Four types of tools were tested: Single Crystal Diamond (SCD), cBN, Tungsten Carbide (WC), and CVD-SiC.
- Cutting Parameters: Turning was performed with a constant depth of cut (2 µm) and varying feed rates (0.5, 1, 2, 5, 10 mm/min). Total cutting distance was 2.39 km/pass.
- Tool Wear Evaluation: Tool wear was measured in situ without removing the tool. A replica of the tool edge shape was created by plunge-cutting the diamond tool into an acrylic resin plate.
- Measurement: The replica shape was measured using a laser probe scanning non-contact measuring device (NH-3UP). Tool wear ratio was calculated as (Workpiece Removal Volume) / (Tool Wear Volume).
- Surface Roughness Measurement: Surface roughness (Rz) was measured using a non-contact surface roughness meter (New View 6200).
6CCVD Solutions & Capabilities
Section titled “6CCVD Solutions & Capabilities”This research confirms that high-quality SCD is indispensable for achieving the demanding surface finishes required for advanced biomedical applications like Ti implant texturing. 6CCVD is positioned as the premier supplier of the foundational SCD material necessary to manufacture these high-performance micro-cutting tools.
Applicable Materials
Section titled “Applicable Materials”To replicate or extend this research, the highest quality, low-defect SCD material is required to ensure tool longevity and minimize chipping during ultra-precision machining.
| 6CCVD Material | Specification | Application Relevance |
|---|---|---|
| Optical Grade SCD | High purity, low nitrogen content, minimal defects. | Ideal for manufacturing the SCD micro-cutting tools used in the study, ensuring maximum hardness and thermal stability. |
| Engineering Grade SCD | Suitable for larger tool inserts or substrates where extreme optical clarity is not the primary requirement. | Cost-effective option for high-volume tool production or backing plates. |
| Polycrystalline Diamond (PCD) | Available in large formats (up to 125 mm diameter). | While SCD was used for the micro-tool, large-area PCD plates can be used for wear-resistant fixtures or larger scale machining applications. |
Customization Potential
Section titled “Customization Potential”6CCVD’s advanced MPCVD growth and post-processing capabilities directly address the specialized needs of ultra-precision tool manufacturing and implant research.
- Custom Dimensions: We supply SCD plates and wafers up to 500 µm thick, and substrates up to 10 mm thick, allowing tool manufacturers to optimize the size and geometry of the diamond insert for specific micro-cutting applications.
- Ultra-Precision Polishing: The study emphasizes the importance of tool edge quality. 6CCVD offers Ra < 1 nm polishing for SCD, ensuring the starting material is perfectly prepared for subsequent tool grinding and shaping, which is critical for achieving the low Rz values reported (down to 500 nm Rz).
- Metalization Services: The paper notes that Ti implants often require surface modification. 6CCVD offers in-house metalization (Au, Pt, Pd, Ti, W, Cu) on diamond substrates, a capability highly relevant for researchers developing advanced diamond-based biomedical sensors or functionalized implant coatings.
- Laser Cutting and Shaping: We provide custom laser cutting services to achieve precise geometries, ensuring the SCD blanks meet the exact specifications required for micro-tool fabrication.
Engineering Support
Section titled “Engineering Support”The complex interaction between tool wear, thermal properties (SCD’s high thermal conductivity minimizes heat transfer to the workpiece), and surface finish requires expert material selection.
- In-House PhD Team: 6CCVD’s engineering team, composed of PhD-level material scientists, can assist researchers and tool manufacturers in selecting the optimal SCD grade, crystal orientation, and thickness for similar micro-machining projects targeting high-wear, high-precision materials like Ti alloys.
- Thermal Management: We provide consultation on how SCD’s superior thermal properties can be leveraged to reduce adhesion and wear, addressing the challenges noted in the paper regarding Ti’s tendency to adhere to the tool surface.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly. We ship globally (DDU default, DDP available).
View Original Abstract
Ti alloy has conventionally been used for parts of air plane or chemical equipment because it is lightweight and strong, and has a property of corrosion resistance. Furthermore, there are few allergies that are superior in living body cell fusion characteristics; is flexible, and have a characteristic to be flexible. These characteristics are most suitable for a dental implant or a total hip prosthesis, and a lot of Ti has been used. However, Ti alloy is a difficult-to-machine material. In this study, Ti was cut by some kind of tool materials such as single crystal diamond, cBN, tungsten carbide and CVD-SiC, and tool wear characteristics and surface roughness changes were evaluated experimentally.