Modification of diamond tool by focused ion beam in dry single-point diamond turning

The modified diamond tools (MDT) by focused ion beam (FIB) can reduce tool wear to a certain extent while avoiding the pollution of traditional cutting fluid. This paper investigates the dry single-point diamond turning (DSPDT) process for Al6061 alloy with MDT. DSPDT tests showed that MDT produced lower cutting forces and generated smoother machined surfaces. Furthermore, MDT has a lighter wear compared with the unmodified diamond tools. The reasons why the cutting performance of MDT is better than the unmodified diamond tools are the reduced surface energy of modified diamonds proved by the first principle calculations and contact angle tests, and the change of the C–C bond energy and bond length according to the first principle calculations. Therefore, it is feasible and promising to apply the MDT in the DSPDT of Al6061 alloy, which will contribute to carbon neutralization manufacturing.