Machining of Acrylic Resin Using Monocrystalline Diamond Endmill with Cutting Edges Formed by Focused Ion Beam
Tsunehisa Suzuki and Hiroshi Saito
Yamagata Research Institute of Technology, 2-2-1 Matsuei, Yamagata 990-2473, Japan
The cutting edge of a single-blade monocrystalline diamond endmill was formed using the Focused Ion Beam technique (FIB): the cutting edge was mechanically polished to a rake angle of -70° and then formed to a rake angle of 0° by FIB sputtering. The performance of the diamond endmill was evaluated for the machining of acryl resin. Grooves were cut into optical acrylic resin with the resulting endmill; characteristics such as the surface roughness, cutting resistance, and chip shape were evaluated. The improved sharpness of the cutting edge reduced the surface roughness and cutting force in the depth direction. The surface roughness did not fluctuate even under the conditions of a fast feed rate and deep cutting depth. A cutter mark was observed on the finished surface, and flowing chips were generated unlike the performance of the -70° rake angle cutter.
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