single-au.php

IJAT Vol.13 No.1 pp. 58-66
doi: 10.20965/ijat.2019.p0058
(2019)

Paper:

Cutting Characteristics of Direct Milling of Cemented Tungsten Carbides Using Diamond-Coated Carbide End Mills with Untreated and Treated Cutting Edge

Masato Okada*,†, Reiji Suzuki**, Hidehito Watanabe***, Masaaki Otsu*, and Takuya Miura*

*Faculty of Engineering, University of Fukui
3-9-1 Bunkyo, Fukui-City, Fukui 910-8507, Japan

Corresponding author

**Graduate School of Engineering, University of Fukui, Fukui, Japan

***Tool Engineering Department, UNION TOOL Co., Mitsuke, Japan

Received:
June 15, 2018
Accepted:
October 9, 2018
Published:
January 5, 2019
Keywords:
cemented tungsten carbide, diamond-coated carbide end mill, cutting force, tool wear behavior, finished surface
Abstract

This study investigates the cutting characteristics of direct milling of cemented tungsten carbides performed using a diamond-coated carbide end mill. The diamond-coated carbide end mills have cutting edges that are both treated and untreated, and the sharp cutting edge can be developed at the ridgeline of the diamond coating on the flank face via treatment of the cutting edge. Two types of cemented tungsten carbide were used as workpiece materials, i.e., TAS VM-40 and VC-70. The influence of the cutting length on the cutting characteristics was also studied. In the case of cutting of the VM-40, the cutting force of the treated tool was significantly lower than that of the untreated tool. The cutting forces of both tools were observed to be similar after the diamond coating on the rake face of the untreated tool was flaked. The cutting edge at the ridgeline of the diamond coating on the flank face of both tools was retreated during the cutting progress, and the thickness of the diamond coating of the untreated tool was also decreased. The finished surface integrity was drastically altered owing to the flaking of the diamond coating on the rake face of the untreated tool and the irregularity of the cutting edge of both tools. The accuracy of the machined shape obtained by using the treated tool was better than that obtained using the untreated tool, and the tendency was significantly observed as the cutting progressed. In the case of cutting of VC-70, flaking of the diamond coating of untreated tool did not occur, and the cutting force of the treated tool was significantly lower than that of the untreated one. The cutting edge of the treated tool was maintained sharp up to a groove length of 500 mm, although the workpiece material was clearly observed to be adhering to the round corner of the cutting edge of the untreated tool. Moreover, the accuracy of the shape of the machined groove obtained using the treated tool was better than that obtained using the untreated tool.

Cite this article as:
M. Okada, R. Suzuki, H. Watanabe, M. Otsu, and T. Miura, “Cutting Characteristics of Direct Milling of Cemented Tungsten Carbides Using Diamond-Coated Carbide End Mills with Untreated and Treated Cutting Edge,” Int. J. Automation Technol., Vol.13 No.1, pp. 58-66, 2019.
Data files:
References
  1. [1] R. Matsumoto, N. Kai, Y. Tomita, A. Kajioka, S. Mori, and H. Utsunomiya, “Characterization of surface profile of shot peened cemented tungsten carbide dies with micro valleys and their lubrication performance in cold forging,” Proc. Eng., Vol.207, pp. 1135-1140, 2017.
  2. [2] R. Lu, L. Minarro, Y.-Y. Su, and R. M. Shemenski, “Failure mechanism of cemented tungsten carbide dies in wet drawing process of steel cord filament,” Int. J. Refract. Met. Hard Mater., Vol.26, No.6, pp. 589-600, 2008.
  3. [3] M. Takada, H. Matsubara, and Y. Kawagishi, “Wear of cemented carbide dies for steel cord wire drawing,” Mater. Trans., Vol.54, No.10, pp. 2011-2017, 2013.
  4. [4] F. Klocke, L. Chrubasik, A. Klink, and L. Hensgen, “Analysis of fundamental process characteristics for sinking-EDM of cemented carbides as a function of polarity,” Proc. CIRP, Vol.68, pp. 313-318, 2018.
  5. [5] F. Klocke, M. Holsten, and A. Klink, “Technological and economic investigations on the application of metal infiltrated graphite electrodes for the sinking EDM of cemented carbides,” Proc. CIRP, Vol.42, pp. 632-637, 2016.
  6. [6] H. Obara, H. Satou, and M. Hatano, “Fundamental study on corrosion of cemented carbide during wire EDM,” J. Mater. Process. Technol., Vol.149, No.1-3, pp. 370-375, 2004.
  7. [7] M. G. Xu, J. H. Zhang, Y. Li, Q. H. Zhang, and S. F. Ren, “Material removal mechanisms of cemented carbides machined by ultrasonic vibration assisted EDM in gas medium,” J. Mater. Process. Technol., Vol.209, No.4, pp. 1742-1746, 2009.
  8. [8] M. R. Shabgard, M. A. Badamchizadeh, G. Ranjbary, and K. Amini, “Fuzzy approach to select machining parameters in electrical discharge machining (EDM) and ultrasonic-assisted EDM processes,” J. Manuf. Sys., Vol.32, No.1, pp. 32-39, 2013.
  9. [9] M. P. Jahan, Y. S.Wong, and M. Rahman, “Evaluation of the effectiveness of low frequency workpiece vibration in deep-hole micro-EDM drilling of tungsten carbide,” J. Manuf. Process., Vol.14, No.3, pp. 343-359, 2012.
  10. [10] T. Tamura, “Development of on-th-machine surface modification technology in EDM,” Proc. CIRP, Vol.6, pp. 117-122, 2013.
  11. [11] S. H. Lee and X. Li, “Study of the surface integrity of the machined workpiece in the EDM of tungsten carbide,” J. Mater. Process. Technol., Vol.139, No.1-3, pp. 315-321, 2003.
  12. [12] M. P. Jahan, Y. S. Wong, and M. Rahman, “A study on the fine-finish die-sinking micro-EDM of tungsten carbide using different electrode materials,” J. Mater. Process. Technol., Vol.209, No.8, pp. 3956-3967, 2009.
  13. [13] H. Juhr, H.-P. Schulze, G. Wollneberg, and K. Künanz, “Improved cemented carbide properties after wire-EDM by pulse shaping,” J. Mater. Process. Technol., Vol.149, No.1-3, pp. 178-183, 2004.
  14. [14] Y. H. Ren, B. Zhang, and Z. X. Zhou, “Specific energy in grinding of tungsten carbides of various grain sizes,” CIRP Annals, Vol.58, No.1, pp. 299-302, 2009.
  15. [15] F. Klocke, C. Wirtz, S. Mueller, and P. Mattfeld, “Analysis of the material behavior of cemented carbides (WC-Co) in grinding by single grain cutting tests,” Proc. CIRP, Vol.46, pp. 209-213, 2016.
  16. [16] W. F. Habrat, “Effect of bond type and process parameters on grinding force components in grinding of cemented carbide,” Proc. Eng., Vol.149, pp. 122-129, 2016.
  17. [17] A. Okada, R. Kitada, Y. Okamoto, and Y. Uno, “Surface modification of cemented carbide by EB polishing,” CIRP Annals, Vol.60, No.1, pp. 575-578, 2011.
  18. [18] A. Beaucamp, Y. Namba, W. Messelink, D. Walker, P. Charlton, and R. Freeman, “Surface integrity of fluid jet polished tungsten carbide,” Proc. CIRP, Vol.13, pp. 377-381, 2014.
  19. [19] K. Liu, X. P. Li, M. Rahman, and X. D. Liu, “CBN tool wear in ductile cutting of tungsten carbide,” Wear, Vol.255, No.7-12, pp. 1344-1351, 2003.
  20. [20] J. Fujiwara, K. Wakao, and T. Miyamoto, “Influence of tungsten-carbide and cobalt on tool wear in cutting of cemented carbides with polycrystalline diamond tool,” Int. J. Automation Technol., Vol.7, No.4, pp. 433-438, 2013.
  21. [21] H. Suzuki, T. Furuki, M. Okada, K. Fujii, and T. Goto, “Precision cutting of structured ceramic molds with micro PCD milling tool,” Int. J. Automation Technol., Vol.5, pp. 277-282, 2011.
  22. [22] K. Nakamoto, T. Aoyama, K. Katahira, P. Fonda, and K. Yamazaki, “A study of nanometric surface generation on tungsten carbide using a micro polycrystalline diamond end mill,” Int. J. Automation Technol., Vol.6, No.4, pp. 547-553, 2012.
  23. [23] M. Okada, A. Yoshida, T. Furumoto, H. Watanabe, N. Asakawa, and M. Otsu, “Mechanisms and characteristics of direct cutting of tungsten carbide using a diamond-coated carbide end mill,” Int. J. Manuf. Technol., Vol.86, No.5-8, pp. 1827-1839, 2016.

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, Opera.

Last updated on Dec. 02, 2024