Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate

Zhou, Tianfeng; Ruan, Benshuai; Zhou, Jia; Dong, Xiaobin; Liang, Zhiqiang; Wang, Xibin

doi:10.1007/s40436-019-00260-7

Cited by 5 publications

(4 citation statements)

References 27 publications

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“…They attribute this phenomenon to the fact that a high rake angle enhances tensile stress in the cutting region, causing the material to fracture. Zhou et al [94] fabricated micro lens arrays on PMMA with a high-quality surface, and the tool used in the machining had a zero-degree rake angle. The undeformed chip thickness must be less than ∼890 nm to ensure the ductile mode cutting at low cutting speed.…”

Section: Rake/relief Anglesmentioning

confidence: 99%

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Huang

Yan

2023

Int. J. Extrem. Manuf.

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Brittle materials are widely used for producing important components in the industry of optics, optoelectronics, and semiconductors. Ultraprecision machining of brittle materials with high surface quality and surface integrity helps improve the functional performance and lifespan of the components. According to their hardness, brittle materials can be roughly divided into hard-brittle and soft-brittle ones. Although there have been some literature reviews for ultraprecision machining of hard-brittle materials, up to date, very few review papers are available that focus on the processing of soft-brittle materials. Due to the “soft” and “brittle” properties, this group of materials has unique machining characteristics. This paper presents a comprehensive overview of recent advances in ultraprecision machining of soft-brittle materials. Critical aspects of machining mechanisms such as chip formation, surface topography, and subsurface damage for different machining methods, including diamond turning, micro end milling, ultraprecision grinding, and micro/nano burnishing, are compared in terms of tool-workpiece interaction. The effects of tool geometries on the machining characteristics of soft-brittle materials are systematically analyzed, and dominating factors are sorted out. Problems and challenges in the engineering applications are pointed out, and solutions/guidelines for future R&D are provided.

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Section: Rake/relief Anglesmentioning

confidence: 99%

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Huang

Yan

2023

Int. J. Extrem. Manuf.

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“…In order to find the minimum value, the partial derivatives of formula (16) need to be obtained respectively, and then:…”

Section: Ls-svm Verification Model Error 51 Ls-svm Calculation Principlementioning

confidence: 99%

“…It has a certain reference significance. Zhou [8] studied the influence of the diamond tool on the undeformed chip thickness, feed rate and tool trajectory on chip fracture during the cutting process, and proposed a two-way cutting method, which proved the shape error and surface roughness of the processed part through experiments. The degree is improved.…”

Section: Introductionmentioning

confidence: 99%

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Prediction of tool wear on workpiece surface quality based on milling topography analysis

Zhang

Zheng

et al. 2022

Preprint

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The surface quality of the workpiece has a great impact on the performance of the product. It has always been a key issue of the manufacturing discipline. The different wear levels of cutting tools determine the surface quality of the workpiece. Therefore, the work of this article is to establish a model for calculate the surface quality of the workpiece after milling. First, by defining the tool wear area S and the wear position angle ψ , the cutting edge line model of the tool is determined. Based on the tool motion trajectory and roughness calculation principle, a milling topography simulation roughness model considering tool wear is obtained. Secondly, the tool wear parameters were calibrated with the help of image detection methods, and the predicted values obtained by the model were compared with the experimental values. The law of the influence of the tool wear area S and the wear position angle ψ on the roughness parameters was obtained. Finally, the least squares support vector machine LS-SVM was used to verify the error of the roughness model of the milling topography simulation, and the result showed that the average error of the model was 8.68%.

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Improvement of dimensional accuracy and surface quality of microlens arrays by a profile cutting method

Zhou

Ruan

et al. 2021

Int J Adv Manuf Technol

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Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate

Cited by 5 publications

References 27 publications

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Effect of tool geometry on ultraprecision machining of soft-brittle materials: a comprehensive review

Prediction of tool wear on workpiece surface quality based on milling topography analysis

Improvement of dimensional accuracy and surface quality of microlens arrays by a profile cutting method

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