Ultra-precision diamond turning of optical silicon—a review

Abdulkadir, Lukman N.; Abou-El-Hossein, Khaled; Jumare, Abubakar I.; Odedeyi, Peter Babatunde; Liman, Muhammad Mukhtar; Olaniyan, Tirimisiyu A.

doi:10.1007/s00170-017-1529-x

Cited by 64 publications

(29 citation statements)

References 226 publications

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“…( a ) Face milling setup with the cutting tool and force dynamometer, and micro-geometry of the ( b ) honed and ( c ) chamfered (T-land) cutting edge and ( d ) cutting edge forms with parametric edge dimensions (adapted from [36]).…”

Section: Figurementioning

confidence: 99%

Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

et al. 2019

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Intermittent machining using ceramic tools such as hard milling is a challenging task due to the severe mechanical shock that the inserts undergo during machining and the brittleness of ceramic inserts. This study investigates the machinability of hardened steel AISI 1045 during face milling using SiAlON and whisker (SiCW) based ceramic inserts. The main focus seeks to identify the effects of cutting parameters, milling configuration, edge preparation and work material hardness on machinability indicators such as resultant cutting force, power consumption and flank tool wear. The effects of these varying cutting conditions on performance characteristics were investigated using a Taguchi orthogonal array design L32 (21 44) and evaluated using ANOVA. Results indicate lower resultant cutting forces were recorded with honed edge inserts of SiAlON ceramic grade. In addition, a decrease in resultant cutting forces was associated with reduced feed rates and increased hardness. The feed rate and cutting speed were also identified as the greatest influencing factors in the amount of cutting power. The main wear mechanisms responsible for flank wear on the ceramic inserts are micro-scale abrasion and micro-chipping. Increased flank wear was observed at low cutting speed and high feed rates, while micro-chipping mostly ensued from the cyclic loading of the radial tool edge form, which is more susceptible to impact fragmentation. Thus, the use of tools with chamfered tool-edge preparation greatly improved observed wear values. Additional confirmation tests were also conducted to validate the results of the tests.

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Section: Figurementioning

confidence: 99%

Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

et al. 2019

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“…In order to withstand the irradiation of high-power laser, it is necessary to avoid SSD as much as possible in the machining technologies for fused silica. Ultra-precision grinding, as an efficient and economical manufacturing technology for optical elements, is one of the important technologies for processing high-precision and high-quality fused silica [7][8][9][10][11][12]. But the surface and subsurface of fused silica after ultra-precision grinding usually contains SSD.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on surface integrity and subsurface damage of fused silica in ultra-precision grinding

Zhong

Dai

Xiao

et al. 2021

Int J Adv Manuf Technol

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To realize low-damage ultra-precision grinding on fused silica, the surface quality and subsurface damage (SSD) distribution with fine-grained grinding wheel under different depth-of-cut and cutting speed are experimentally studied. The material removal mechanism under different grinding parameters is revealed by calculating undeformed chip thickness and observed with the help of transmission electron microscopy. The results show that brittleductile surfaces and ductile-like surfaces are generated during grinding. With the decrease of depth-of-cut and the increase of wheel cutting speed, the ultra-precision grinding changes to ductile-regime grinding with plastic flow removal. Besides, the surface roughness (SR) and SSD depth are reduced. The fracture defects such as fractured pits and grinding streaks on brittle-ductile surface gradually decrease. Instead, a ductile-like surface covered with grinding streaks is found. On brittle-ductile surfaces, the nonlinear relationship SSD∝SR 4/3 is no longer proper under the influence of plastic flow. Using surface roughness Ra to predict SSD depth is more accurate. When depth-of-cut is 1 μm, cutting speed is 23.4 m/s and the material removal mode is dominated by plastic flow removal, the surface Ra is improved to 2.0 nm and there is no crack but only a 3.4 nm deep plastic flow layer in subsurface after grinding.

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“…From discrepancy of the classical models, the commonly-produced lamellar chips in ultra-precision machining, 10–12 widely applied into many advanced manufacturing fields with sub-micrometric form accuracy and nanometric surface roughness 13–16 indicate that the shear angle changes along with chip formation but not keep constant, i.e. cyclic shear angle.…”

Section: Introductionmentioning

confidence: 99%

Cyclic shear angle for lamellar chip formation in ultra-precision machining

Zhang

Guo

Zhang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Shear angle is classically considered constant. In the study, a series of straight orthogonal cutting tests of ultra-precision machining revealed that shear angle cyclically evolved with each lamellar chip formation, i.e. cyclic shear angle. It grew up from an initial shear angle of 0° to a final shear angle 90°- α ( α: tool rake angle) and underwent a series of transient shear angles like classical shear angles and a critical shear angle. The critical shear angle is the sum of the half of the tool rake angle and the characteristic shear angle determined by material anisotropy without the friction effect. Moreover, a new model was developed. Further, a series of face turning tests of ultra-precision machining verified that the cyclic shear angle was the intrinsic mechanism of cyclic cutting forces and lamellar chip formation to induce twin-peak high-frequency multimode diamond-tool-tip vibration. Significantly, the study draws up an understanding of shear angle for the discrepancy among the classical models.

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Ultra-precision diamond turning of optical silicon—a review

Cited by 64 publications

References 226 publications

Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Experimental study on surface integrity and subsurface damage of fused silica in ultra-precision grinding

Cyclic shear angle for lamellar chip formation in ultra-precision machining

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