Micro-machining of ferrous materials using diamond tool
with ionized coolant and carbon particles
Dr. Sangkee Min
Lawrence Berkley National Laboratory
A shift from prototyping to mass manufacturing for parts and components of emerging applications such as alternative energy devices, biomedical instruments, etc. demands ultra precision mold fabrication on hard materials. In particular, utilizing a diamond tool on ferrous materials to create precise patterns or features has been a big challenge in die and mold industry. Chemical reactions between carbon atoms and iron atoms, however, cause a significant wear of the diamond tool and prevent its use on ferrous materials. In this presentation, a new method to enable diamond tool to cut ferrous materials will be discussed. A special coolant, called ion-shot coolant, was developed to protect the diamond tool. The effects of the new coolant (ion-shot coolant) which consists of ionized coolant and carbon particles on two steel materials, a high carbon chromium steel and a pre-hardened mold steel were investigated. Also mechanism of the ion-shot cutting was discussed by the observation on material structure at the primary shear zone and frictional coefficient between diamond tool and ferrous material. The ion-shot coolant showed great potential for the used of the diamond tool on ferrous material in terms of tool wear and surface quality.
Date(s) - 01/16/2014
4:00 pm - 5:00 pm