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<p>Achieving precise cutting edge radius control in the nanosecond laser sharpening of polycrystalline diamond (PCD) tools is challenging because of complex thermal–material interactions. This study investigates the influence of scanning trajectories and process parameters using a dual-stage “primary cutting and secondary polishing” strategy. The experimental results reveal that compared with conventional circular paths, a helical scanning trajectory reduces the edge radius by 46.5%. The outermost line spacing is identified as the critical factor for process stability. Insufficient spacing induces excessive graphitization and catastrophic edge failure. Furthermore, a nonmonotonic relationship is observed between the secondary polishing depth and the resulting radius. On the basis of these findings, a Gaussian process regression (GPR) model is established for target-oriented radius control. The model achieves a minimum radius of <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\:5.9\:{\upmu\:}\text{m}\)</EquationSource> </InlineEquation>, which is comparable to that of picosecond laser processing, and demonstrates a predictive accuracy of 8.42% (MAPE) in independent validation. This framework transforms empirical optimization into a deterministic manufacturing method for the customized preparation of PCD cutting edges, offering process guidance and a theoretical basis for preparing PCD tool cutting edges according to different target-specific cutting edge radii.</p>

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A target-oriented control method for the cutting edge radii in the nanosecond laser machining of PCD cutting tools

  • 期刊论文

  • 发表日期：

    2026年5月9日

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  • Yushun Zhang,
  • Fuzhu Han

摘要

Achieving precise cutting edge radius control in the nanosecond laser sharpening of polycrystalline diamond (PCD) tools is challenging because of complex thermal–material interactions. This study investigates the influence of scanning trajectories and process parameters using a dual-stage “primary cutting and secondary polishing” strategy. The experimental results reveal that compared with conventional circular paths, a helical scanning trajectory reduces the edge radius by 46.5%. The outermost line spacing is identified as the critical factor for process stability. Insufficient spacing induces excessive graphitization and catastrophic edge failure. Furthermore, a nonmonotonic relationship is observed between the secondary polishing depth and the resulting radius. On the basis of these findings, a Gaussian process regression (GPR) model is established for target-oriented radius control. The model achieves a minimum radius of \(\:5.9\:{\upmu\:}\text{m}\) , which is comparable to that of picosecond laser processing, and demonstrates a predictive accuracy of 8.42% (MAPE) in independent validation. This framework transforms empirical optimization into a deterministic manufacturing method for the customized preparation of PCD cutting edges, offering process guidance and a theoretical basis for preparing PCD tool cutting edges according to different target-specific cutting edge radii.