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21 Thomas, JD, Ceramic tools find new applications, Manufacturing Engineering, May 1985, 34 39 22 <http://wwwseicojp/RandD/itami/e-tool/toolmaterialshtml> [online] 23 Greenleaf Corporation, The Application of Whisker Reinforced Ceramic/Ceramic Composites, Saegertown, PA, USA, 1989 24 Santhirakumar, B, Performance of Whisker Reinforced Ceramic Insert during Hard Turning, MSc Thesis, Universiti Teknologi Malaysia, 2003 25 Swinehart, H J, Cutting Tool Material Selection, American Society of Tool and Manufacturing Engineers, 1968 26 Avner, SH, Introduction to Physical Metallurgy, McGraw Hill Co, 1974 27 Van Vlack, LH, Elements of Materials Science, Addison-Wesley Publishing Company, 1959 28 Porat, R, Selecting Crystallographic Planes and Directions for Minimum Wear and Minimum Friction Coefficient in a Single Crystal Diamond Cutting Tool, Iscar Ltd, Tefen, Israel 29 Brookes, CA, Indentation Hardness of Diamond, Diamond Research, 1971 30 Porat, R, MSc Thesis The Technion Haifa, 1971 31 Shaw, MC, Metal Cutting Principles, Oxford University Press, 2005 32 Wentorf, RH, Borazon, CBN and Man Made Diamond Compacts, Ibid, 511 524 33 Horton, MD and Horton, LB, Grades of polycrystalline diamond, Proc SME s Conference on Super abrasives 85, Chicago, April 1985, 1 9 34 Feinberg, B, Cutting tools: 1974, Manufacturing Engineering and Management, January 1974, 27 33 35 Clark, IE PCD wood tools a new design concept , Woodworking, 1993, Vol 2, 73 76 36 DeBeers Diamond Division, Introduction to PCD and PCDN Cutting Tool Materials, Berkshire, UK, 1993 37 Venkatesh, VC and Enomoto, S, Finishing methods using defined cutting edges, ASM Handbook, Vol 5, Surface Engineering, 1994, 84 89 38 Davis, RF, Diamond Films and Coating, Noyes Publications, USA, 1993 39 John, BW and Richard, AH, Ceramic Films and Coating, Noyes Publications, USA, 1993 40 Hintermann, HE and Chattopadhyay, AK, Low pressure synthesis of diamond coatings, Annals of the CIRP, 1993, Vol 42, 769 783 41 Choo, TKD, Performance and Wear of Single Crystal Diamond and Polycrystalline Diamond Tools during Precision Turning of Ductile Materials, B Eng Thesis, Nanyang Technological University, Singapore, 1996 42 Zhang, JH, Theory and Technique of Precision Cutting, Pergamon Press, Oxford, 1991 43 Wentorf, RH, Devries, RC and Bundy FP, Sintered super hard materials, Science, 1980, 208, 873 80 44 Harris, TK, Brookes, EJ and Taylor, CJ, Journal of Refractory Metals and Hard Materials, 2004, 22, 105 110 45 Matsumoto, K and Diniz, AE, Evaluating quality of hardened steel work pieces, Journal of Brazilian Society of Mechanical Sciences, 1999, 21 (2), 343 354 46 Chou, YK and Evans, C J, Cubic boron nitride tool wear in interrupted hard cutting, Wear, 1999, 234 245 47 Diniz, AE, and Gomes DM, Journal of Material Processing Technology, 2004 48 Poulachon, G, Bandyopadhyoy, BP and Jawahir, IS, Wear, 2004, 256, 302 310 49 Thiele, JD and Melkote, SN, Journal of Material Processing Technology, 1999, 94, 216 226 50 Quinto DT, Journal of Refractory Metals and Hard Materials, 1996, 14, 7 20 51 Oles, E, et al, Coated PCBN cutting inserts, United States Patent, July 29, 2003
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21 Describe CVD and PVD coating processes and indicate how they can improve wear resistance 22 Discuss diamond coated carbides, PCDs (Polycrystalline Diamonds) and single crystal diamonds 23 Design a single crystal diamond tool for turning silicon, similar to the one shown in Figure 230 Assume a side rake angle of 45 degrees
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Investigators in the metal cutting field have attempted to develop an analysis of the cutting process that gives a clear understanding of the mechanism involved and enables the prediction of important cutting parameters, without the need for empirical testing As most practical cutting operations are geometrically complex, we shall first consider the simple case of orthogonal cutting (ie, cutting with the cutting edge perpendicular to the relative velocity between the work piece and the tool), and extend the theories to more complicated processes Because of its simplicity and fairly wide application, the continuous chip without a built-up edge has been most thoroughly studied and will be the major topic of this chapter In the last 30 years, many papers have been written on the basic mechanics of metal cutting Several models to describe the process have been developed; some have been fairly successful in describing the process, but none can be fully substantiated and definitely stated to be the correct solution [1] Thus, while none of the analyses can precisely predict conditions in a practical cutting situation, the analyses are worth examining because they can qualitatively explain the phenomena observed and indicate the direction in which conditions should be changed to improve cutting performance [1, 2] An often-encountered macro scale machining condition, namely, orthogonal turning is commonly done on a lathe, but turning can also be done on a milling machine In turning, the purpose is generally to reduce the diameter of the workpiece The edge is assumed to be very sharp compared to the depth of the cut (uncut chip thickness) Therefore, the actual rake angle is the same as the geometric rake angle If the rake face (the surface upon which the cut chip slides as it leaves the cutting zone) is tilted towards the direction of tool travel, then the rake angle is negative Because the
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