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

Warhanek, Maximilian; Pfaff, Josquin; Martı́n, P.; Schönbächler, Lukas; Boos, Jens; Wegener, Konrad

doi:10.1016/j.procir.2016.04.003

Cited by 14 publications

(4 citation statements)

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“…Successful attempts on implementing ductile milling on hard and brittle materials, such as engineering ceramics and carbide, have been conducted recently [ 26 , 27 , 28 ]. Matsumura and Ono [ 29 ] reported that grooves with axial depth of cut in the range of 15–20 μm can be machined in glass if the CBN ball end mill is tilted at a certain angle in the feed direction.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on Ductile Mode Micro-Milling of ZrO2 Ceramics with Diamond-Coated End Mills

et al. 2018

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ZrO2 ceramics are currently used in a broad range of industrial applications. However, the machining of post-sintered ZrO2 ceramic is a difficult task, due to its high hardness and brittleness. In this study, micro-milling of ZrO2 with two kinds of diamond-coated end mills has been conducted on a Kern MMP 2522 micro-milling center (Kern Microtechnik GmbH, Eschenlohe, Germany). To achieve a ductile mode machining of ZrO2, the feed per tooth and depth of cut was set in the range of a few micrometers. Cutting force and machined surface roughness have been measured by a Kistler MiniDynamometer (Kistler Group, Winterthur, Switzerland) and a Talysurf 120 L profilometer (Taylor Hobson Ltd., Leicester, UK), respectively. Machined surface topography and tool wear have been examined under SEM. Experiment results show that the material can be removed in ductile mode, and mirror quality surface with Ra low as 0.02 μm can be achieved. Curled and smooth chips have been collected and observed. The axial cutting force Fz is always bigger than Fx and Fy, and presents a rising trend with increasing of milling length. Tool wear includes delamination of diamond coating and wear of tungsten carbide substrate. Without the protection of diamond coating, the tungsten carbide substrate was worn out quickly, resulting a change of tool tip geometry.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigation on Ductile Mode Micro-Milling of ZrO2 Ceramics with Diamond-Coated End Mills

et al. 2018

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“…Recently, ultra-short pulsed laser systems are becoming more affordable and increasingly applied by industry [11]. An example is the production of cutting tools, like end mills and drills with diamond cutting edges [12,13]. The kinematics of quasi-tangential laser processing is similar to the wire electric-discharge machining (EDM) process and the developed CAM models [14] can be facilitated partially.…”

Section: Introductionmentioning

confidence: 99%

Path calculation of 7-axes synchronous quasi-tangential laser manufacturing

Ackerl

Warhanek

Gysel

et al. 2019

Int J Adv Manuf Technol

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Quasi-tangential laser processing, also called laser turning is increasingly applied for various applications. Specifically, its ability to generate complex geometries with small feature sizes at high precision and surface quality in hard, brittle and electrically non-conductive materials. Due to the geometric flexibility, the process is well suited for prototyping in hard-to-machine materials such as ceramics, carbides and super-abrasives. However, the lack of advanced software solutions for this novel process hitherto limited the exploitation of this potential. Here, we discuss a unique computer-aided manufacturing approach for synchronous 7axis laser manufacturing with quasi-tangential strategies. This gives the peerless possibility to process arbitrary geometries, which cannot be manufactured with conventional techniques. A detailed description of the path calculation with derivation and procedures is given. The generated machine code is tested on a 7-axis laser manufacturing setup. Following, a processed cylindrical ceramic specimen with a continuously varying profile along a helical path is presented. The profile is constituted by a rectangular over half-spherical to a triangular groove with defined pitch. This demonstrator provides the validation of this CAM solution. Measurements of the produced specimen show high adherence with the target geometry with an average deviation below 10 µm.

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“…However, laser machining in quasi-tangential configuration at high pulse energy leads to cracks on the surface. The quasi-tangential laser machining using a 5-axis kinematic was successfully applied for manufacturing of polycristalline diamond end mills by Warhanek et al [ 11 ] as well as tungsten carbide end mills by Pfaff et al [ 12 ]. A model describing the angle dependent ablation characteristic of fused silica and sapphire was published by Boerner et al [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

Laser Ablation Study of Cutting Ceramics with Consideration of the Beam Inclination Angle

et al. 2023

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Silicon alumina nitride (SiAlON) and alumina toughened zirconia (ATZ) ceramics are applied for ceramic cutting tools to machine, e.g., cast iron, nickel base alloys and other difficult-to-machine materials. The state of the art technology for manufacturing of the cutting tool geometry is grinding. Laser processing of ceramics is already studied in terms of ablation rate and roughness evaluation with the application of dental implant manufacturing. In the present study, laser machining of the mentioned ceramics is explored with a laser beam source of 1064 nm wavelength and 10 ps pulse duration (FWHM). The angle dependent energy specific removal rate is described in a model and the optimal pulse fluence for the different materials and the irradiation angles can be derived. For processing at irradiation angle of up to 75° no decrease of the relative absorption could be observed. For ATZ, lowest surface roughness is determined for both, orthogonal and quasi-tangential processing angle. For SiAlON, the roughness decreases constantly for higher tilt angles. A significant difference in the material answer with change of the sample composition can be detected and the results show the potential of further developing SiAlON ceramics towards machineability for laser ablation.

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

Cited by 14 publications

References 10 publications

Experimental Investigation on Ductile Mode Micro-Milling of ZrO2 Ceramics with Diamond-Coated End Mills

Experimental Investigation on Ductile Mode Micro-Milling of ZrO2 Ceramics with Diamond-Coated End Mills

Path calculation of 7-axes synchronous quasi-tangential laser manufacturing

Laser Ablation Study of Cutting Ceramics with Consideration of the Beam Inclination Angle

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