Mechanism of Hole Wall Blackening in PCD Dry Reaming and Its Synergistic Suppression via Texture-MQL-Abrasive

YE Weihao; SHI Chenchun; YU Aibing; QU Zhenbao; JIN Miaojie; HUANG Zikang

doi:10.16490/j.cnki.issn.1001-3660.2026.15.007

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Surface Technology ›› 2026, Vol. 55 ›› Issue (15) : 78-96. DOI: 10.16490/j.cnki.issn.1001-3660.2026.15.007

Precision and Ultra-precision Machining

Mechanism of Hole Wall Blackening in PCD Dry Reaming and Its Synergistic Suppression via Texture-MQL-Abrasive

YE Weihao^1a, SHI Chenchun^1a,1b,2,*, YU Aibing^1a, QU Zhenbao³, JIN Miaojie^1a, HUANG Zikang^1a

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Abstract

Dry and near-dry reaming are important approaches to achieve green and precision machining of aluminum alloys. However, polycrystalline diamond (PCD) reamers tend to induce periodically distributed black streaks on the hole wall surface during the machining of aluminum alloys, which impairs the surface quality. Therefore, it is necessary to clarify the formation mechanism and explore suppression methods. In this work, a combination of multiple analytical methods was adopted. The macro/micro-topography of the hole wall was observed by laser confocal microscopy and scanning electron microscopy. The elemental composition and phase composition of the blackened areas were characterized by energy dispersive spectroscopy and X-ray diffraction. Meanwhile, the vibration signals during the reaming process were collected online by a laser Doppler vibrometer, and combined with the finite element simulation based on the Johnson-Cook material model, the thermal-mechanical coupled numerical simulation of the temperature field in the cutting zone was carried out. The analysis results show that the periodically distributed black streaks on the hole wall surface are amorphous aluminum oxide coatings with vacancy-type defects. Their formation is attributed to the intermittent extrusion and friction between the reamer margin and the hole wall induced by reaming vibration, which leads to local temperature rise and further promotes the periodic accumulation and formation of oxide films. To suppress the blackening phenomenon, the work aims to design and prepare functional textures on the margin surface of reamers. In the preliminary experiments, the pit texture with a spacing of 300 μm was initially selected as the optimal option, which was then applied to PCD reamers for dry reaming experiments of aluminum alloys. However, experimental results showed that although the blackening could be alleviated to a certain extent, under the impact of cutting vibration, the edges of the textures acted as micro-cutting edges instead, exerting additional micro-cutting effects on the hole wall and resulting in an increase in the surface roughness as well as a decrease in the roundness and cylindricity of the hole wall. To solve the above problem, a synergistic near-dry reaming scheme was proposed, comprising "composite textured tool + minimum quantity lubrication (MQL)+free abrasive finishing". In this scheme, groove textures were fabricated on the rake face of PCD reamers to capture the lubricant mixed with diamond abrasives pre-coated on the hole wall, and relying on the centrifugal force generated by the rotation of the reamer, the mixture was continuously transported to the cutting zone and the margin-hole wall interface, so as to reduce the friction coefficient and cutting force, thereby mitigating the impact of reaming vibration. Meanwhile, pit textures with oil storage and chip accommodation functions were machined on the margin surface, and the hole wall surface was polished with diamond micro-particles. The experimental results indicated that the proposed near-dry reaming scheme achieved remarkable effectiveness. The blackening phenomenon on the hole wall was basically eliminated. Compared with the original dry reaming process, the surface roughness of the hole wall was reduced by approximately 51.0%, and the roundness and cylindricity errors decreased by about 29.9% and 30.5%, respectively, exhibiting better machining quality and process stability.

Key words

reaming / surface texture / margin / aluminum alloy / friction

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YE Weihao, SHI Chenchun, YU Aibing, QU Zhenbao, JIN Miaojie, HUANG Zikang. Mechanism of Hole Wall Blackening in PCD Dry Reaming and Its Synergistic Suppression via Texture-MQL-Abrasive[J]. Surface Technology. 2026, 55(15): 78-96

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Funding

National Natural Science Foundation of China (52405491); Ningbo University-Jiangbei District "Double First-Class" Collaborative Special Entrusted Science and Technology Cooperation Project (2436); Ningbo Natural Science Foundation (2024J044); Ningbo Beilun District Key Core Technology Research Project (2025BLG011); the Fundamental Research Funds for the Provincial Universities of Zhejiang (SJLY2025001)