Performance and wear analysis of polycrystalline diamond (PCD) tools manufactured with different methods in turning titanium alloy Ti-6Al-4V

Polycrystalline diamond (PCD) tools have been widely used in industry because of its ultra-hardness and high abrasion resistance. Electrical discharge grinding (EDG) and conventional abrasive grinding are currently the two main processes to manufacture PCD tools. However, PCD tools fabricated by the two methods show different cutting performance. This paper investigates the quality and performance of PCD tools manufactured by the two methods in turning titanium alloy. Flank wear, crater wear, tool nose wear, and their mechanisms were investigated; residual stress and graphitization were analyzed quantitatively by using Raman spectrum. Although PCD tools machined with the two methods do not have obvious big difference in visible surface quality, serious tool wear was found on the surface and cutting edge of the conventionally ground PCD tool, while PCD tools machined with EDG process showed better tool wear resistance. Through analysis of Raman spectrum, compressive residual stress of 0.54 GPa was found on the surface of conventionally ground PCD tool. In contrast, larger tensile residual stress was found on the PCD tools manufactured with EDG process.