Ultra-precision machining of electroless-nickel plated die material

Abstract

This study is an attempt (a) to optimize various cutting parameters, (b) to study and compare the performance of two types of diamond tools and (d) to investigate the effect of depth-of-cut on artificial diamond cutter for very long cutting distance during ultra-precision machining of electroless-nickel. The experimental results show that higher feedrate gives worse surface and higher cutting forces, however with the increase of phosphorus content surface becomes better and cutting forces decrease. It appears that depth-of-cut does not have any significant effect on surface roughness but cutting forces increase with the increase of depth-of-cut, and for increasing spindle speed cutting forces increase slightly but there is a critical speed for best surface. It was found that natural diamond cutter performed better than that of artificial diamond cutter and electroless-nickel with higher phosphorus gave better surface finish and tool performance. Machining with lower depth-of-cut gave higher tool wear though the performances in other aspects were nearly same as higher depth-of-cut.