Analysis on ductile mode processing of binderless, nano crystalline tungsten carbide through ultra precision diamond turning

Ultra precision diamond turning is usually applied for processing non ferrous metals, plastics and a few single crystal materials. The machining of hard and brittle material, such as nano crystalline, binderless tungsten carbide has only been investigated within a few publications on a theoretical basis and applying nano indenting. Therefore the goal of this paper is to qualify the ultra precision diamond turning technique for processing nano crystalline, binderless tungsten carbide applying the real process conditions identifying optimal parameters. A potential application of this process would be the mold manufacturing for precision glass molding. Within a systematical procedure the ductile to brittle transition is analyzed as well as the tool wear, varying both, tool geometry and processing parameters. Based on material analysis the critical depth of cut for the material was calculated at 165 nm. This value could be validated in the experiments at the optimal cutting speed of 50 m/min with a feed of 1 μm. Least tool wear was observed at a tool radius of 0.4 mm and a rake angle of −20°. The experiments demonstrate the strong influence of the processing conditions on the achieved results.