Estimation of Cutting Conditions in Precision Micromachining of CuNi Alloys of Varying Composition

A non-dimensional model is developed that relates cutting edge temperatures to process inputs (speed and feed) and outputs (cutting and thrust forces) as well as tool and work thermal properties in micromachining with diamond tools. The temperature estimates are used to determine activation energy for thermally activated chemical wear of a PCD tool milling Monel 400 (Cu 32, Ni 65 wt%). Activation energy estimates are from 15 to 60 kJ/ mole, depending on systematic uncertainties, such as diamond thermal conductivity, that still need to be addressed.