In this study, performance evaluations are carried out for single crystal diamond tools with tool point angles of 45° and 60° in the machining of V-shape micro grooves on electroless nickel plated die materials. The performance evaluation is based on tool wear with the wear criterion set at 1 μm nose wear for the cutting of 5 μm deep V-groove. In order to evaluate the cutting performances, cutting parameters such as infeed rate, cutting speed and lubricant material were varied. In the initial stage of cutting for both types of cutter, a chipped-off area on the flank edge at a distance away from the cutting zone was observed for several cutting conditions. This wear did not directly affect the cutting of the micro grooves as it was observed that wear on the tool tip was mostly gradual. However in some cases of the 45° tools, a catastrophic failure of tool tip occurred before reaching the wear criteria. The experimental results show that under similar cutting conditions, the 60° tools are able to achieve longer groove cutting distances compared to the 45° tools.
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