A Study on Diamond Turning of Al-Mg Alloy (1st Report)

Influence of Tool Setting Angle on Machined Surface Roughness

Abstract

A machined surface roughness can be generally improved at a small geometrical surface roughness estimated by both a tool shape and a feed rate, even if a steady vibration exists between a tool and a workpiece. However, tool setting angles for straight tool are extremely effective upon a machined surface roughness. This paper deals with diamond turning experiments of Al-Mg alloy using straight tools with sharp cutting edges. The effect of tool setting angles on machined surface roughness was examined to study the difference between the machined surface roughness and the theoretical surface roughness estimated with a steady vibration model. Tears with 0.1 μm depth which are generated on the side cutting edge deteriorate the machined surface roughness. The tears are cut off by the trailing end cutting edge at a negative tool setting angle. Burrs generated at the tool setting angle less than -0.1° are another cause for the deteriorating the machined surface roughness.