単結晶ダイヤモンドエンドミルによる鉄系材料の超精密切削(<小特集>生産加工・工作機械の規範2008)

抄録

In general, the three-dimensional free curved dies of iron based alloy have been engraved with the coated carbide tool or the CBN tool. In this case, it is difficult to get high accuracy surface, without abrasion process after engraving process. Because diamond is the hardest material in naturally occurring minerals, single crystal diamond tools have sharp edge that tool commonly used for ultra precision cutting. However, it has long been known that tool wear is excessive when diamond tools are used to cut steel or iron based alloy. In this paper, end milling, which is an intermittent cutting operation, was utilized to suppress wear on the single crystal diamond tool for cutting steel. End milling is commonly used to produce free curved surface parts. The work material was stainless steel (SUS420J2) 2mm×5mm in size. In the basic experiment, it was found that the utilization of mist is affective to reduce tool wear, but is no effective to improve surface roughness. Surface roughness was improved by the tool geometry, and clearance angle and swing radius have to be determined properly to consider cutting conditions. The selected experimental conditions of clearance angle of 20° and swing radius of 2mm, the fine machining surface can be obtained, and the surface roughness was around 100nm Rz.