Geometry Optimization of Polycrystalline Diamond Tools for the Milling of Sintered ZrO2

Abstract Recent developments on tangential ultrashort-pulsed laser processing enable the generation of solid polycrystalline diamond composite tools with increasing geometric flexibility. To exploit this potential, an experimental study on the influence of the tool geometry on the cutting characteristics and the tool wear while milling sintered Zirconia dioxide is conducted. Three different tool geometries and a variation in rake and flank angles are produced to investigate the effects on processing forces and tool lifetime. The results are applied to the design of an end mill achieving 1.2 mm 3 /mm s specific material removal rate over a tool lifetime of 8000 mm 3 /mm.