Wear characteristics of V shape diamond tool for micro prism pattern with Al alloys

Proceedings of the Institution of Mechanical Engineers, Part B:

Wang

et al. 2016

In order to achieve the high-quality roller mold used in roll-to-roll fabrication of optical prism films, this article investigates the effects of cutting parameters on surface quality during diamond turning of micro-prism array, and some cutting experiments are carried out on home-made ultra-precision drum roll lathe. The surface defects such as micro pits and burrs are presented and discussed at different cutting parameters. The experimental results show that, when the cutting depth is more than 4 mm, the plowing force becomes the dominant factor to remove material, which may cause the generation of micro pits on the side surface of micro prism. During multiple-step diamond turning of micro-prism array, the final cutting depth is recommended not to exceed 2 mm; in this case, there is no generation of micro pits and the height of burr is less than 13.6 nm. Moreover, the well-controlled cooling and chip evacuation can effectively improve the influence of cutting speed on surface quality. Finally, micro-prism array with pitch of 40 mm is successfully machined without apparent surface defects.

Section: Introductionmentioning

confidence: 99%

Effect of cutting parameters on surface quality during diamond turning of micro-prism array

Proceedings of the Institution of Mechanical Engineers, Part B:

Wang

et al. 2016

“…However, the tool wear is severe in the SPDT of the large scale aluminum alloy mirror. Many research work has been done to investigate the diamond tool wear in the SPDT of aluminum alloy [10,11], but the influence of the tool wear on the cutting temperature has not be considered. The change of the cutting temperature will reduce the surface error of the large mirrors.…”

Section: Introductionmentioning

confidence: 99%

The Study of the Influence of Tool Wear on Cutting Temperature in Diamond Ultra-Precision Cutting of Aluminum Alloy Mirror

Dong

Zhou

2016

KEM

This paper performed a series of finite element method (FEM) simulation to investigate the influence of the tool wear on the cutting temperature in the diamond ultra-precision cutting of the aluminum alloy mirror. The two-dimensional FEM model including the diamond tool with the different average width of wear land on flank face was established. A series of ultra-precision cutting experiments using different cutting distance was performed. The tool wear was detected by scanning electron microscopy (SEM), and the cutting temperature was detected by infrared thermal imager. The comparison of the simulation investigations and the experimental investigations was done. The results revealed that the cutting temperature increases with an increase of the average width of wear land on flank face in the FEM simulation. And in the ultra-precision cutting experiments the diamond tool wear becomes severe as the cutting distance increases, meanwhile the severe tool wear results in the higher cutting temperature. Consequently the FEM simulations prove to be right.

“…In order to imporve the machining efficiency and meet the requirements of suface error and suface roughness, diamond ultra-precision cutting is used as finish machining to manufacture large metal mirrors [9,10]. But a multitude of heat generated during the long distance cutting process will influence the tool wear, which reduces the suface error of the large metal mirrors [11,12].…”

Section: Introductionmentioning

confidence: 99%

Simulation and Experiment Study on Cutting Temperature in Diamond Ultra-Precision Cutting of Aluminum Alloy Mirror

Dong

Zhou

2015

KEM

The aluminum alloys are widely used to manufacture large mirror of infrared band optical systems because they have many advantages such as low cost, low mass density, well thermal conductivity, well plasticity and easy manufacturing. In order to imporve the machining efficiency and meet the requirements of suface error and suface roughness of large metal mirror, diamond ultra-precision cutting is used as finish machining to manufacture them. But the diamond tool wear is severe which is induce by the cutting heat and the cutting force during the cutting process. In this work, the metal cutting finit element sofeware-AdvantEdge has been used to study the cutting tempreture in diamond ultra-precision cutting of aluminum alloy, the influence rules of cutting parameters and tool geometric parameters are researched. And the diamond ultra-precesion cutting experiments were performed, the cutting temperature were detected by infrared thermal imager. The results show that the cutting speed exerts the most considerable influence on the cutting temperature, and the cutting temperature increases with an increase in the cutting speed. Although the temperature detected by the infrared thermal imager in the diamond ultra-precesion cutting experiments is lower than that obtained from the simulation of finit element method (FEM), the varied trend of the cutting temperature is the same. So the FEM simulation proves to be true.