Experimental study on the meso-scale milling of tungsten carbide WC-17.5Co with PCD end mills

doi:10.1007/s40436-020-00298-y

Abstract

Abstract: Tungsten carbide is a material that is very difficult to cut, mainly owing to its extreme wear resistance. Its high value of yield strength, accompanied by extreme brittleness, renders its machinability extremely poor, with most tools failing. Even when cutting with tool materials of the highest quality, its mode of cutting is mainly brittle and marred by material cracking. The ductile mode of cutting is possible only at micro levels of depth of cut and feed rate. This study aims to investigate the possibility of milling the carbide material at a meso-scale using polycrystalline diamond (PCD) end mills. A series of end milling experiments were performed to study the effects of cutting speed, feed per tooth, and axial depth of cut on performance measures such as cutting forces, surface roughness, and tool wear. To characterize the wear of PCD tools, a new approach to measuring the level of damage sustained by the faces of the cutter's teeth is presented. Analyses of the experimental data show that the effects of all the cutting parameters on the three performance measures are significant. The major damage mode of the PCD end mills is found to be the intermittent micro-chipping. The progress of tool damage saw a long, stable, and steady period sandwiched between two short, abrupt, and intermittent periods. Cutting forces and surface roughness are found to rise with increments in the three cutting parameters, although the latter shows signs of reduction during the initial increase in cutting speed only. The results of this study find that an acceptable surface quality (average roughness R_a<0.2 μm) and tool life (cutting length L>600 mm) can be obtained under the conditions of the given cutting parameters. It indicates that milling with PCD tools at a meso-scale is a suitable machining method for tungsten carbides.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00298-y

Key words: Tungsten carbide, Meso-scale milling, Polycrystalline diamond (PCD) end mill, Cutting force, Surface roughness, Tool wear

Wei Zhao, Asif Iqbal, Ding Fang, Ning He, Qi Yang. Experimental study on the meso-scale milling of tungsten carbide WC-17.5Co with PCD end mills[J]. Advances in Manufacturing, 2020, 8(2): 230-241.

TrendMD

References

1. Ottersbach M, Zhao W (2016) Experimental investigations on the machinability of tungsten carbides in orthogonal cutting with diamond-coated tools. Procedia CIRP 46:416-419
2. Zhao W, Yang Q, Khan AM et al (2019) An inverse-identification-based finite element simulation of orthogonal cutting tungsten carbide. J Braz Soc Mech Sci Eng 41:1-12
3. Krain HR, Sharman ARC, Ridgway K (2007) Optimisation of tool life and productivity when end milling Inconel 718TM. J Mater Process Technol 189(1/3):153-161
4. Fang ZZ (2005) Correlation of transverse rupture strength of WCCo with hardness. Int J Refract Met H 23(2):119-127
5. Saito H, Iwabuchi A, Shimizu T (2006) Effects of Co content and WC grain size on wear of WC cemented carbide. Wear 261(2):126-132
6. Li T, Li Q, Fuh JYH et al (2006) Effects of lower cobalt binder concentrations in sintering of tungsten carbide. Mater Sci Eng A 430(1/2):113-119
7. Liu K, Li XP (2001) Ductile cutting of tungsten carbide. J Mater Process Technol 113(1/3):348-354
8. Arif M, Rahman M, San WY (2012) Analytical model to determine the critical conditions for the modes of material removal in the milling process of brittle material. J Mater Process Technol 212(9):1925-1933
9. Suzuki H, Okada M, Fujii K et al (2013) Development of micro milling tool made of single crystalline diamond for ceramic cutting. CIRP Ann Manuf Technol 62(1):59-62
10. Nakamoto K, Katahira K, Ohmori H et al (2012) A study on the quality of micro-machined surfaces on tungsten carbide generated by PCD micro end-milling. CIRP Ann Manuf Technol 61(1):567-570
11. Liu K, Li XP, Rahman M (2003) CBN tool wear in ductile cutting of tungsten carbide. Wear 255(7/12):1344-1351
12. Zhang J, Suzuki N, Wang Y et al (2014) Fundamental investigation of ultra-precision ductile machining of tungsten carbide by applying elliptical vibration cutting with single crystal diamond. J Mater Process Technol 214(11):2644-2659
13. Tamaki JI, Kubo A, Ullah AS (2014) Wear characteristics of nano-polycrystalline diamond tool in cutting of tungsten carbide. Int J Mechatron Manuf Syst 7(4/6):227-245
14. Zhan Z, He N, Li L et al (2015) Precision milling of tungsten carbide with micro PCD milling tool. Int J Adv Manuf Technol 77(9/12):2095-2103
15. Kuppuswamy R, Mkhize N (2017) Near ductile regime machining of tungsten carbide insert through control of cutting speed parameter while using a poly-crystalline diamond tool. Procedia Manuf 8:549-556
16. Wojciechowski S, Nowakowski Z, Majchrowski R et al (2017) Surface texture formation in precision machining of direct laser deposited tungsten carbide. Adv Manuf 5(3):251-260
17. Doetz M, Dambon O, Klocke F et al (2018) Process control in ductile mode machining of tungsten carbide. In:The 5th European seminar on precision optics manufacturing, Teisnach, Germany. https://doi.org/10.1117/12.2318709
18. Sakamoto S, Suwa H, Moriwaki T (2017) Wear properties of diamond-coated ball end tools in milling of tungsten carbide. In:JSME, proceedings of international conference on leading edge manufacturing in 21st century, Hiroshima City, Japan. https://doi.org/10.1299/jsmelem.2017.9.050
19. Suzuki H, Okada M, Asai W et al (2017) Ultraprecision cutting of silicon carbide using micro milling tool of single crystalline diamond. In:JSME, proceedings of international conference on leading edge manufacturing in 21st century. https://doi.org/10.1299/jsmelem.2017.9.084
20. Katahira K, Ohmori H, Takesue S et al (2015) Effect of atmospheric-pressure plasma jet on polycrystalline diamond micromilling of silicon carbide. CIRP Ann Manuf Technol 64(1):129-132
21. Okada M, Yoshida A, Furumoto T et al (2016) Mechanisms and characteristics of direct cutting of tungsten carbide using a diamond-coated carbide end mill. Int J Adv Manuf Technol 86(5/8):1827-1839
22. Minami T, Itoigawa F, Maegawa S et al (2015) Basic study on failure process of CVD diamond coating tool in machining of cemented carbide materials. In:JSME, proceedings of international conference on leading edge manufacturing in 21st century, Kyoto, Japan. https://doi.org/10.1299/jsmelem.2015.8.0522-1
23. Goel S, Luo X, Comley P et al (2013) Brittle-ductile transition during diamond turning of single crystal silicon carbide. Int J Mach Tool Manuf 65:15-21
24. Yui A, Kitajima T, Krajnik P et al (2014) Effect of cutting fluid on diamond tool life under micro V-groove turning of cobalt-free tungsten carbide. Adv Mater Res 1017:181-186
25. Bian R, Ferraris E, He N et al (2014) Process investigation on meso-scale hard milling of ZrO₂ by diamond coated tools. Precis Eng 38(1):82-91
26. Mia M, Bashir MA, Khan MA et al (2017) Optimization of MQL flow rate for minimum cutting force and surface roughness in end milling of hardened steel (HRC 40). Int J Adv Manuf Technol 89(1/4):675-690
27. Singh G, Gupta MK, Mia M et al (2018) Modeling and optimization of tool wear in MQL-assisted milling of Inconel 718 superalloy using evolutionary techniques. Int J Adv Manuf Technol 97(1/4):481-494
28. Li H, Lai X, Li C et al (2007) Modelling and experimental analysis of the effects of tool wear, minimum chip thickness and micro tool geometry on the surface roughness in micro-endmilling. J Micromech Microeng 18(2):1-12

[1]	Chao-Jun Zhang, Song-Qing Li, Pei-Xuan Zhong, Fei-Fan Zhang, Wen-Jun Deng. Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining [J]. Advances in Manufacturing, 2025, 13(2): 395-412.
[2]	Zhen-Jing Duan, Shuai-Shuai Wang, Shu-Yan Shi, Ji-Yu Liu, Yu-Heng Li, Zi-Heng Wang, Chang-He Li, Yu-Yang Zhou, Jin-Long Song, Xin Liu. Surface quality evaluation of cold plasma and NMQL multi-field coupling eco-friendly micro-milling 7075-T6 aluminum alloy [J]. Advances in Manufacturing, 2025, 13(1): 69-87.
[3]	Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Dao-Hui Xiang, Zi-Ang Liu, Chuan Qian, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu. Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation [J]. Advances in Manufacturing, 2025, 13(1): 88-104.
[4]	Xin Wang, Qing-Liao He, Biao Zhao, Wen-Feng Ding, Qi Liu, Dong-Dong Xu. Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys [J]. Advances in Manufacturing, 2025, 13(1): 155-166.
[5]	Jin Zhang, Li Ling, Qian-Yue Wang, Xue-Feng Huang, Xin-Zhen Kang, Gui-Bao Tao, Hua-Jun Cao. Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform [J]. Advances in Manufacturing, 2024, 12(2): 349-364.
[6]	Long-Hua Xu, Chuan-Zhen Huang, Zhen Wang, Han-Lian Liu, Shui-Quan Huang, Jun Wang. Novel intelligent reasoning system for tool wear prediction and parameter optimization in intelligent milling [J]. Advances in Manufacturing, 2024, 12(1): 76-93.
[7]	Guo-Liang Liu, Jin-Tao Zheng, Chuan-Zhen Huang, Shu-Feng Sun, Xin-Fu Liu, Long-Jie Dai, De-Xiang Wang, Xiang-Yu Wang. Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061 [J]. Advances in Manufacturing, 2023, 11(4): 663-681.
[8]	Xue-hong Shen, Chang-Feng Yao, Liang Tan, Ding-Hua Zhang. Prediction model of surface integrity characteristics in ball end milling TC17 titanium alloy [J]. Advances in Manufacturing, 2023, 11(3): 541-565.
[9]	Lorcan O'Toole, Feng-Zhou Fang. Optimal tool design in micro-milling of difficult-to-machine materials [J]. Advances in Manufacturing, 2023, 11(2): 222-247.
[10]	Chang-Yong Yang, Zhi Wang, Hao Su, Yu-Can Fu, Nian-Hui Zhang, Wen-Feng Ding. Numerical analysis and experimental validation of surface roughness and morphology in honing of Inconel 718 nickel-based superalloy [J]. Advances in Manufacturing, 2023, 11(1): 130-142.
[11]	Vitor F. C. Sousa, Francisco J. G. Silva, Ricardo Alexandre, José S. Fecheira, Gustavo Pinto, Andresa Baptista. Experimental study on the wear evolution of different PVD coated tools under milling operations of LDX2101 duplex stainless steel [J]. Advances in Manufacturing, 2023, 11(1): 158-179.
[12]	Jiang Guo, Xing-Yu Wang, Yong Zhao, Chen-Yi Hou, Xu Zhu, Yin-Di Cai, Zhu-Ji Jin, Ren-Ke Kang. On-machine measurement of tool nose radius and wear during precision/ultra-precision machining [J]. Advances in Manufacturing, 2022, 10(3): 368-381.
[13]	Long-Xu Yao, Zhan-Qiang Liu, Qing-Hua Song, Bing Wang, Yu-Kui Cai. Effects of process parameters on periodic impact force exerting on cutting tool in ultrasonic vibration-assisted oblique turning [J]. Advances in Manufacturing, 2022, 10(3): 411-427.
[14]	Ming-Xian Xu, Liang-Shan Xiong, Bao-Yi Zhu, Ling-Feng Zheng, Kai Yin. Experimental research on the critical conditions and critical equation of chip splitting when turning a C45E4 disc workpiece symmetrically with a high-speed steel double-edged turning tool [J]. Advances in Manufacturing, 2022, 10(2): 159-174.
[15]	Kai-Ning Shi, Ning Liu, Cong-Le Liu, Jun-Xue Ren, Shan-Shan Yang, Wei Chit Tan. Indirect approach for predicting cutting force coefficients and power consumption in milling process [J]. Advances in Manufacturing, 2022, 10(1): 101-113.