Micro-grooving of brittle materials using textured diamond grinding wheels shaped by an integrated nanosecond laser system

Abstract

Freeform surfaces including both the aspherical and prismatic concave/convex have been widely utilized in optical, electronical, and biomedical areas. Most recently, it is reported that grinding with structured wheels provides new possibility to generate patterns on hard and brittle materials. This paper reports the latest research progress on micro-grooving glass ceramic using laser structured diamond grinding wheels. A nanosecond pulse laser is firstly integrated into an ultra-precision machine tool and used for the in-line conditioning of super abrasive grinding wheels, i.e., truing, dressing, and profiling/texturing. Meanwhile, an offset compensation method, considering the shifting depth of focus (DoF) at different laser irradiation positions, is proposed to accurately generate various profiles on the periphery of the grinding wheels. Three types of patterns (riblets, grooves, and pillars) are successfully fabricated on the ceramic substrate using the laser textured grinding wheels. The results indicate that the integrated laser system offers high flexibility and accuracy in shaping super abrasive grinding wheels, and the grinding using textured grinding wheels provides a promising solution to generate functional microstructures on hard and brittle materials.

Texturing Methods of Abrasive Grinding Wheels: A Systematic Review

“…The effects of ultrafast laser ablation on grinding wheel groove morphologies were investigated. In engineering practice, the laser machining model suggested by Geng et al [98] offers a condition for the superabrasive grinding wheel with more efficiency and adaptability. A nanosecond pulse laser was incorporated into an ultra-precision machine tool and utilized for in-line grinding wheel conditioning, dressing, and texturing.…”

“…A nanosecond pulse laser was incorporated into an ultra-precision machine tool and utilized for in-line grinding wheel conditioning, dressing, and texturing. To create precise profiles on the grinding wheel surface, an offset compensation approach taking into account the fluctuating depth of focus at different laser irradiation positions was developed [97,98].…”

Subpicosecond laser ablation behavior of a magnesium target and crater evolution: Molecular dynamics study and experimental validation

“…Short-pulse laser ablation of metal materials is a core technology in engineering applications, such as high-precision cutting, drilling, and the fabrication of nano-functional and nano-bionic structures. [1][2][3] Currently, research on the mechanisms of laser ablation of materials has yielded significant results. [4][5][6][7] The response of metal materials to laser irradiation is complex and includes electron excitation through photon absorption, transient modification of metal physical properties, relaxation of laser-induced stresses, non-equilibrium phase transformations, plasma formation and shielding phenomena.…”

A strategy of hob-grinding the cylindrical riblet surface for drag reduction using the grinding wheel with ordered abrasive pattern

“…In terms of using pro led grinding wheels to grind riblets, Denkena B et al [7][8][9][10][11] conducted research on the in uence of grinding wheel wear, dressing, and feeding strategies on the generating mechanism of riblet surface during the riblet grinding process on the blade surface, and invented a simulated beaver tooth structured grinding wheel, which signi cantly improved the grinding e ciency; Xie J et al [12,13] achieved good drag reduction effects by grinding micro grooves (or riblets) on the front face of the turning tool and the revolution body surface through precise dressing with grinding wheels; Geng Z C et al [14] successfully achieved the grinding of micro grooves (or riblets) on the surface of ceramic samples by using nanosecond laser beams to trim diamond grinding wheels; Guo B et al [15,16] achieved the grinding of structured surfaces with groove and pyramid shapes by nely shaping V-shaped diamond grinding wheels using mechanical methods and dressing rough diamond grinding wheels using lasers.…”