doi: 10.3850/978-981-11-0749-8_744
On the Development of a Chip breaker in Metal-Matrix PCD Insert
Ahmed Elkaseer1,2,a,b, Jon Lambarri1,c and Jon Ander Sarasua1,d
11IK4-TEKNIKER, c/I ñaki Goenaga 5, Eibar, Gipuzkoa, 20600, Spain
aahmed.elkaseer@tekniker.es
cjon.lambarri@tekniker.es
djonander.sarasua@tekniker.es
2Department of Production Engineering & Mechanical Design, Faculty of Engineering, Port Said University, Port Said, 42523, Egypt
belkaseeram@gmail.com
Abstract
This paper reports on the development of an original chip breaker in metal-matrix polycrystalline diamond (MMPCD) insert brazed into a milling tool. The performance of MMPCD material was characterised under a wide range of ablation conditions (laser power level, pulse duration and frequency) and feed speed, by ablating single trenches. The results, in terms of ablation rates and profiles of the trenches generated were processed and fed into a simulation tool that was developed based on the recently published work of Cadot et al., (2016). This made it possible to examine the outcomes (e.g. the resultant thickness of ablated layers) when applying different process conditions, and to predict the obtainable shape when ablating multi-layers. Next, the geometry of the designated chip breaker was sliced into a number of layers to be ablated sequentially. Different ablation scenarios, layer thickness, ablation strategy and setting of the focal plane, were investigated to identify the processing conditions for optimum performance of the laser ablation process. The preliminary results showed that a ns-laser was successfully utilised in a controllable and repeatable manner to produce the necessary 3D features of an intricate chip breaker with high surface quality (Ra was in the sub-micron range) and tight dimensional accuracy (maximum dimensional error was less than 4%) and in an acceptable processing time (≈51 seconds).
Keywords: Metal-matrix PCD, Chip breaker, ns laser, Surface quality, Dimensional accuracy.
