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Investigation of tool life in the single-crystal diamond turning of AISI 420 using high-frequency ultrasonic vibration

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Abstract

AISI 420 is primarily used for optic molds manufactured through ultraprecision machining with single-crystal diamond tools. Tool wear rapidly occurs due to the diffusion of diamond and iron atoms when cutting ferrous metals with diamond tools. In the machining of optic molds, the diamond tool is uniformly replaced, regardless of the tool status after use for some time due to the difficulty in predicting tool life. This practice results in the wastage of expensive single-crystal diamond tools and reduces productivity. This study addressed the aforementioned issue by developing a tool-life model through theoretical analysis of the effective contact ratio between the tool and the workpiece and a cutting experiment with high-frequency ultrasonic vibration. In addition, the effectiveness of ultrasonic vibration cutting on the suppression of diamond tool wear was demonstrated by measuring tool wear after the cutting experiments.

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Acknowledgments

This work was supported by the National Research Foundation of Korea grant funded by the Korean government (MSIT) (RS-2023-00278890).

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Authors and Affiliations

  1. Center for Advanced Cutting Tool, Daegu Mechatronics and Material Institute, 3 Seoungseogongdan-ro, Dalseo-gu, Daegu, 42715, Korea

    Il Chae Yoon & Ik Soo Kang

  2. School of Mechanical Engineering, Yeungnam University, 280 Daehak-ro, Gyeongsan, Gyeongbuk, 38541, Korea

    Il Chae Yoon, Ye In Kwak, Rendi Kurniawan & Tae Jo Ko

Authors
  1. Il Chae Yoon
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  2. Ik Soo Kang
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  3. Ye In Kwak
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  4. Rendi Kurniawan
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  5. Tae Jo Ko
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Corresponding authors

Correspondence to Rendi Kurniawan or Tae Jo Ko.

Additional information

Il Chae Yoon is a Ph.D student at Mechanical Engineering, Yeungnam University. He received his B.S. and M.S. from Yeungnam University, South Korea. His research interests are ultraprecision machining, ultrasonic vibration-assisted machining, and cutting tool performance.

Ik Soo Kang is a Principal Researcher at Daegu Mechatronics & Materials Institute. He received his Ph.D. degree from the School of Mechanical Engineering, Pusan National University, South Korea. His research interests include artificial intelligence application to machining and cutting tools.

Ye In Kwak is a Ph.D. student at Mechanical Engineering, Yeungnam University. He received his B.S. and M.S. from Yeungnam University, South Korea. Mr. Kwak is mainly engaged in research related to surface texturing of the machining process.

Rendi Kurniawan is currently an Assistant Professor at Yeungnam University, South Korea. He received his B.Eng. degree from Universitas Indonesia, Indonesia. His received his M.S. and Ph.D. degrees from Yeungnam University, Korea. His research interests are surface texturing and elliptical vibration texturing.

Tae Jo Ko is a Professor of Mechanical Engineering at Youngman University, South Korea. He received his B.S. and M.S. from the Pusan National University, South Korea and Ph.D. from POSTECH, Korea. His research interests include machine tools, metal cutting and nontraditional machining, surface texturing using metal cutting, grinding, and bio-machining.

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Yoon, I.C., Kang, I.S., Kwak, Y.I. et al. Investigation of tool life in the single-crystal diamond turning of AISI 420 using high-frequency ultrasonic vibration. J Mech Sci Technol 38, 2519–2526 (2024). https://doi.org/10.1007/s12206-024-0430-4

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  • DOI: https://doi.org/10.1007/s12206-024-0430-4

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