Diamond tool wear mode, path and tip temperature distribution considering effect of varying rake angle and duncut/Redge ratio

Diamond tool wear has been proven to strongly depend on the temperature at the cutting zone. This is because the elevated temperature so attained during machining not only lowers carbon cohesion energy thereby reducing the fracture toughness of diamond tool due to C-C bond weakening but also facilitates high rate of carbon diffusion from diamond tool into silicon workpiece leading to high tool wear. This research therefore studied the response of diamond tool wear path and mode to changing rake angle and d u n c u t R e d g e ratio during ultraprecision single point diamond turning of a monocrystalline silicon. It was observed from the study that the tool with larger rake angle and high d u n c u t R e d g e ratio experienced stronger cutting resistance from the workpiece thereby causing the kinetic friction to be high. Additionally, silicon carbide (Tribochemistry) formation was observed to be through both solid-state single phase and multiphase reaction which are in tandem with sp3-sp2 disorder (graphitization) of diamond with bulk of the observed tool wear happening in the flank face which could be due to increasing rake angle influence on the changing d u n c u t R e d g e ratio.