Micro cutting of pure tungsten using self-developed polycrystalline diamond slotting tools

This paper focused primarily on an experimental investigation of micro cutting of pure tungsten. Polycrystalline diamond (PCD) micro slotting tools were developed and used in the experiments. Cutting forces, surface quality, and burr formation were analyzed under various feeds per tooth and radial depths of cut. The effects of squeezing and rubbing were responsible for erratic force signatures, sharp increases of tangential force, and the variation of surface quality and burr formation at low feeds per tooth. Radial and tangential forces were increased with the increase of both feed per tooth and radial depth of cut. The results of surface quality indicated that a medium level of both feed per tooth and radial depth of cut were favorable. The lowest burrs were produced at a medium level of feeds per tooth, whereas lower burr heights occur at smaller radial depths of cut. In addition, PCD tool wear was studied. The wear of the rake face was more severe than that of the flank face, and the two minor cutting edges exhibited different degrees of wear. Furthermore, the dominant wear patterns were microchipping and flaking of the rake face.