Abstract
Ultraviolet-irradiated precision polishing was applied to the ground flank face of commercial cutting tools to achieve advanced PCD cutting tools. PCD cutting tools with a smooth flank surface and sharpened cutting edge were finally obtained. The cutting edge radius of a sharpened PCD tool was about 87 nm as determined by 3D-SEM. The cutting performance of sharpened PCD cutting tools was investigated by turning tests of aluminum alloy (A5052) and high-silicon aluminum alloy (Al-17%Si, A390). The cutting results confirmed the improvement of surface roughness and calculated diffused reflection rate, and reduction of flank wear. As the flank wear was increased by sharpening of cutting tools in the cutting of high-silicon aluminum alloy, the formation technique of the chamfer with a negative rake angle by UV-polishing was newly developed. The formation of the chamfer could prevent flank wear caused by the impact with the primary Si hard particles.
