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Micro machining of single crystal diamond by utilization of tool wear during cutting process of ferrous material

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The extreme hardness of single crystal diamond makes it an ideal cutting tool for ultraprecision machining. When diamond is used as a product, it should be shaped into a required arbitrary shape. For example, to produce a diamond-cutting tool for ultra-precision grooving, not only polishing, but also shaping diamond into an arbitrary shape is needed. In order to get a bulk pattern, polishing diamond with diamond powder is done extensively, but this method is costly and time consuming. This research is an experimental investigation of the micro machining of single crystal diamonds by ferrous material, in order to get the diamond into an arbitrary shape. Tool wear during the cutting process is utilized. It is found that ferrous material can polish and shape single crystal diamond, even though single crystal diamond is considerably harder than ferrous material. For comparison, machining by other materials has been conducted. The removal rate has been measured. The surface roughness of machined diamond is comparable with the surface roughness of new commercial cutting diamond, and better than laser manufactured surface roughness.


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