Study of Airborne Dust Emission and Process Performance During Dry Machining of Aluminum-Silicon Alloy with PCD and CVD Diamond-Coated Tools

• Published in: Journal of manufacturing processes Vol. 5; no. 2; pp. 163 - 169
• Main Authors: Arumugam, Prabhu U., Malshe, Ajay P., Batzer, Stephen A., Bhat, Deepak G.
• Format: Journal Article
• Language: English
• Published: Oxford Elsevier Ltd 2003; Dearborn, MI Elsevier; Society of Mechanical Engineers; SME
• Subjects: Aerosols; Airborne particulates; Aluminum; Applied sciences; Cutting tools; Design of experiments; Diamond-Coated Tools; Dry Machining; Environmentally Benign Manufacturing; Exact sciences and technology; Health hazards; Indoor air quality; Investigations; Machine tools; Manufacturers; Manufacturing; Mechanical engineering. Machine design; Morphology; Occupational health; Process controls; Scanning electron microscopy; Silicon; Studies; Dry Machining; Environmentally Benign Manufacturing; Diamond-Coated Tools; New product; Silicon alloy; Diamond tool; Polycrystal; Machining; Aluminium alloy; Chemical vapor deposition; Dry machining; Thin film; Dust; Thick film; Cutting fluid; Hard coating; Carbides
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/S1526-6125(03)70051-6

The generation of a fine mist of cutting fluid during conventional wet machining and the associated environmental and operator health concerns make environmentally benign machining and manufacturing a major research thrust both in the scientific and manufacturing communities. In this context, high-speed machining in combination with environmentally benign methods makes diamond-coated tooling a unique candidate for dry machining. Diamond coating research in the past few decades has resulted in new products, one of them being diamond-coated carbide tooling. Diamond in polycrystalline diamond (PCD), chemical vapor deposited (CVD) thin-film (polished and unpolished) and thick-film forms offers unique advantages for dry machining. This paper presents the correlation between diamond tool morphology, machining parameters, nonferrous workpiece properties, and particulate emission in dry machining. These findings provide an important benchmark to gauge the true benefit of diamond tools for dry machining.