Effect of Tool Geometry and Turning Parameters on Cutting Force during Ultra-Precision Diamond Machining of Rapidly Solidified Aluminum (RSA) Alloy 6061

The most important goal of advanced diamond machining is to improve precision and product integrity. Cutting force could have a strong effect on diamond machining performance and hence, it can be used as an indicator for monitoring tool condition for achieving successful machining. Moreover, diamond machining process parameters such as cutting speed, depth of cut and feed rate may strongly influence the process outcomes in terms of surface roughness and tool failure. Diamond machining parameters have a significant role on the cutting force values, and machine-tool stability during ultra-high precision machining that makes use of a natural diamond cutting tool. The main objective of this research work is to investigate the effect of cutting speed, feed rate, depth of cut and nose radius on the cutting force generated during diamond turning of a rapidly solidified aluminum alloy grade called RSA 6061. The effect of nose radius and cutting parameters on cutting force during the ultra-high precision diamond turning process was monitored. The study shows that low speed, low depth of cut and an increase in feed rate at large nose radius consequently results in increase in the cutting force.