A Study on Diamond Turning of Zirconia Ceramics : Influence of Tool Shape on Tool Wear

Abstract

This paper details experimental research to determine problems that should be eliminated to realize ultraprecision machining of ceramics. The performance of a diamond tool with a radiused cutting edge is verified through the measurement of flank wear and cutting force that are created under face turning on partially stabilized zirconia. The same evaluation, varying the cutting conditions, is performed on a tool with a straight cutting edge to restrict the tool wear and accompanied increase of the thrust force. It is shown that the growth of the flank wear on the tool with a radiused cutting edge is accelerated with the decrease in feed rate. This growth occurs because the major cutting edge situated between the nose wear and the groove wear is worn by the increase in rubbing force. Furthermore, it is clarified that the tool wear and the cutting force can be restricted by using a tool with a straight cutting edge, in spite of the fact that the crystallographical orientation of the tool fate id not sufficient to perfectly brotect the growth of the flank wear.