An investigation of machining performance for controlled surface quality requirements in porous tungsten [for dispenser cathodes]

The proposed work in this paper will concentrate on modeling and optimization of face-contour turning of porous tungsten for controlled surface quality requirements. A study of the combined effects of workpiece geometry, work material properties, tool geometry (i.e., cutting edge radius, nose radius, rake angle, inclination angle, etc.), tool material properties (carbide and diamond tool inserts), and machining conditions (cutting speed, depth of cut, and feed) on the porosity in face-contour turning of porous tungsten was undertaken. There are many analyzable characteristics of the cutting phenomenon that can be determined from the output of the system. The empirical data needed for developing accurate modeling equations can be acquired from this output criteria. The cutting edge radius of the tool insert can be measured before and after the machining process with a white light interferometer to determine the initial patterns of wear on the cutting edge. The chips being removed will be gathered and classified. The forces applied to the workpiece will be measured with a multi axis Fischer dynamometer to determine the resultant and component forces at the insert to material interface.