Experiment-based statistical prediction on diamond tool wear in micro grooving NiP alloys

•A new method of predicting diamond tool wear in grooving micro pattern on nickel alloys is introduced.•Wear rate function of cutting speed and depth is driven based on small amount of experiment data.•Statistical approach with reliability and probability factor is applied to improve the wear model.•Tool wear prediction software is developed to supports the machining plan of cutting micro pattern.•Experimental result confirms that the developed model predicts the tool wear of single crystal diamond tool excellently.

Diamond tool wear in grooving micro patterns on nickel alloys has caused an increase in the pattern geometry defect rate over time. Therefore, it is important to be able to understand and predict diamond tool wear and tool life. However, as experiments related to diamond micro grooving are extremely expensive and time consuming, the problem of limited data must be faced. In this paper a new method of predicting diamond tool wear which combines experimental equations with statistics is introduced. The wear model shows the relation of cutting condition, safe wear and probability, which was built by the first experiment. The predicted average wear was the same as the measured value of the verification experiment and the probability was a little smaller than the verification experiment due to the bigger standard deviation of the first experiment, which was not stable compared to the verification experiment.