Experimental investigation of machinability and surface quality of sapphire machined with polycrystalline diamond micro-milling tool

Kazutoshi Katahira, Yuhei Matsumoto, Jun Komotori, Kazuo Yamazaki

Research output: Contribution to journalArticle

3 Citations (Scopus)


Ultra-precision machining of single crystalline sapphire was performed using a polycrystalline diamond (PCD) micro-milling tool. Examination of the machining characteristics indicates that a high-quality surface with a nanometre-scale surface roughness can be obtained when the removed chips are thin enough to achieve ductile-mode machining. Although a high-quality surface was successfully machined, the surface roughness gradually deteriorated and the actual depth of the machined groove became shallower as the machining distance increased because of the build-up of material adhering to the surface of the tool. To retain the milling capabilities of the PCD tool, an electrochemical-assisted surface reconditioning process has been proposed. The reconditioning technique was found to be effective in removing the surface contaminant without causing damage to the edges of the tool.

Original languageEnglish
Pages (from-to)1-10
Number of pages10
JournalInternational Journal of Advanced Manufacturing Technology
Publication statusAccepted/In press - 2017 Aug 7



  • Polycrystalline diamond (PCD) micro-milling tool
  • Single crystalline sapphire
  • Tool reconditioning

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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