The effect of dynamic tool engagement on tool wear and surface integrity in diamond turning of titanium alloys

Ultra-precision machining of titanium alloys is challenging due to severe tool wear and poor surface integrity, which hinders the application of this material in microfabrication. This paper proposes a novel method of diamond turning that enables dynamic tool engagement (DTE) for wear reduction. DTE is realized by the rotation of B-axis (rotary axis of the tool table) and the movement of the tool table, enabling changing engaged cutting edge and a flat machined surface. The tool path is calculated considering the tool nose radius, as well as the relative position of B-axis center and tool nose center. The results indicate that adhesive wear can be significantly reduced when applying DTE in diamond turning of titanium alloys. Additionally, higher tool rotation speeds can further improve this positive effect. Owing to the reduction of tool wear, the surface roughness is also decreased and less adhesions are found on the machined surface produced by DTE.