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The Laser/Water-Jet (LWJ) hybrid machining system, introduced and developed by the Iowa State University’s Laboratory for Lasers, MEMS, and Nanotechnology, was applied to overcome the major deficiencies associated with current ED M and laser machining techniques for shaping Polycrystalline Cubic Boron Nitride (PCBN) cutting tools from the blanks. For PCBN, the purpose of water in LWJ is twofold: phase transformation and t hermal shock. Previously LWJ was used to perform straight line cuts on va rious materials including PCBN. In this work, a further investigation of an understanding of the action of water and two-dimensional contour cutting of PCBN was carried out. The role pl ayed by water in LWJ was compared with that of other fluids (argon, nitrogen, oxygen, and air) to illustrate the effectiveness of water in the controlled fracture mechanism of P CBN. In addition, a twodimensional contour cutting of PCBN using LWJ was investigated by c hanging the crack direction to 60, 108, 120, 135 degrees and following a curve with 1 mm radius in ac cord nce with the standard PCBN tool shapes. The phase transition and the cut qua lity were investigated using Raman spectroscopy, Scanning Electron Microscop y (SEM), and optical profilometer. Results indicated that water is the best medium to control the phase transition and apply the controlled fracture mechanism for PCBN. Also, it was shown that successful cuts were made with obtuse angles in contrast to acute angles . A preliminary qualitative model was presented to explain the observed experimental results.

Investigation of a novel manufacturing technique for two-dimensional machining of Polycrystalline Cubic Boron Nitride (PCBN) tools