Thermal effects in single point diamond turning: Analysis, modeling and experimental study

Single Point Diamond Turning is one of the ultra precision methods to generate surface finish with highest possible dimensional accuracies. It involves material removal by shearing mechanism using a diamond tool tip, shearing of material results in generation of thermal energy which causes adverse impact on the tool wear, dimensional accuracy, and surface quality of work piece and on the cost of production. Thermal issues are generally taken care of by the application of coolant. Even after use of coolant, heat is transferred to workpiece while machining, which contributes to the residue of heat for next machining cycle. It deteriorates the surface quality of machined work piece to some extent. In this work, a mathematical model is proposed to compute the net residual heat transferred in the workpiece in terms of machining parameters. The equations describing temperature distribution inside cylindrical work piece, rate of heat transfer, net residual heat for a constant depth of cut are also computed and presented. The mathematical model is followed by the simulation model and the resultant parametric values through well designed sets of precision machining experiments using proper optimization technique to predict optimum machining combination that result in less distortion of surface quality.