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Dx ball free download chip3/16/2023 ![]() Therefore, in the second operation, a manual polishing process with such as diamond grinding stone is necessary to improve it to the mirror-finished surface. In conventional process of the mold machining the surface quality of tungsten carbide cannot be obtained enough, which requires in range of a single to several ten nanometer-level of surface roughness by fully automated on CNC machining center. The advantage of this method is a significant shortening of the conventional molds/dies making manufacturing process by the reduction of finish grinding time after the rough machining operation. (Nakamoto et al., 2012) shown an ability of the polycrystalline diamond (PCD) end milling of tungsten carbide with large negative rake angle of approximately −30° and down to −60°. S.N.B Oliaei et.,al.(Oliaei & Karpat, 2018) and K. (Suzuki et al., 2013) shown an ability of ductile cutting of tungsten carbide by a single crystal diamond (SCD) milling with negative rake angle of approximately −15°. Jin et., al.(Jin et al., 2007) studied on cutting characteristics of a cubic boron nitride (CBN) ball-nosed end mill having a simple cutting edge without chamfering and center webs with large native rake angle of −45°. In many studies, they used the cutting tools with negative rake angles because the cutting edge strength can be increased and chipping is prevented. In the past decades, several studies have been carried out to achieve ductile-cutting of hard and brittle materials. ![]() However, in the mold machining process of the tungsten carbide, it is well-known as a difficult-to-cut material. Tungsten carbide alloy is widely utilized for mold and die processing, such as press working, die casting, and die forging, due to the material properties are superior to wear resistance and corrosion resistance. As a result, the chips could be generated at down to −75° of rake angles and the relationship between the negative rake angles and the chip generation mechanisms were clarified. Consequently, we designed an experimental setup with a spring constant force for applying simulation of thrust force of the PCD ball-end mill. In this study, to simulate the cutting mechanism of the PCD ball-end mill, an orthogonal cutting experiment was conducted using an ultrafine PCD cutting insert having nose radius similar to that of the PCD ball-end mill, for basically understanding the chip formation mechanism of the PCD ball-end mill. ![]() ![]() However, the mechanism of chip generation in this cutting with the PCD ball-end mills has not been fully clarified. In cutting using the PCD ball-end mills, flow type chips are observed and mirror finish surface without micro fracture can be realized by adopting the ductile-cutting mode. The rake angle varies depending on the depth of cut. The PCD ball-end mill has a distinctive feature of its cutting edge, which it has a simple spherical shape without sharp cutting edge found on conventional cemented carbide and cubic boron nitride (cBN) ball-end mills. A polycrystalline diamond (PCD) ball-end mill is effective for processing molds made of hard and brittle materials, such as cemented carbide and ceramics and having fine and complex shapes with a high aspect ratio. ![]()
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