scholarly journals Nanosecond-Fiber Laser Cutting and Finishing Process for Manufacturing Polycrystalline Diamond-Cutting Tool Blanks

2021 ◽  
Vol 11 (13) ◽  
pp. 5871
Author(s):  
Fuh-Yu Chang ◽  
Chuan-Fu Hsu ◽  
Wen-Hui Lu
Keyword(s):  
Surface Roughness ◽  
Fiber Laser ◽  
Laser Cutting ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
Pulse Frequency ◽  
Layer By Layer ◽  
Processing Depth ◽  
Diamond Cutting Tool ◽  
Cut Surface

This paper presents a nanosecond-fiber-laser-based method for manufacturing polycrystalline-diamond (PCD) tool blanks. The effects of variations in the process path and operating parameters on the cut-surface morphology and surface-quality of the processed PCD workpieces have been analyzed. The results obtained in this study reveal the reactive fusion cutting mechanism to yield a processing depth of 155.2 µm at 30-W average laser power, 200-ns pulse width, and 30-kHz pulse frequency. The successful cutting of a 1.2-mm-thick PCD workpiece via implementation of the horizontal-shifting and vertical layer–by-layer processing methods is reported. Compared to the wire-electrical-discharge machining (WEDM), the proposed approach yields superior cut-surface roughness (Ra = 0.378 µm). Moreover, the laser processing was performed on a single-axis curved stage, on which the workpiece placed at an inclination during laser cutting and finishing. Thus, a PCD insert with an orthogonally cut edge, flat and pit-free finishing surface, and excellent tool-surface roughness (Ra = 0.202 µm) was obtained, thereby verifying the feasibility of the proposed approach. Furthermore, it is evident that the nanosecond-fiber laser can be used to not only cut and finish PCD inserts but also produce PCD workpieces oriented at different rake and clearance angles.

Study on EDM Machining Technics of Polycrystalline Diamond Cutting Tool and PCD Cutting Tool’s Life

2011 ◽  
Vol 268-270 ◽  
pp. 309-315 ◽  
Author(s):  
Yun Hai Jia ◽  
Jian Gang Li ◽  
Xue Jun Lu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Machining Parameter ◽  
Diamond Cutting Tool ◽  
The Relationship

The Samples of Polycrystalline Diamond (PCD) Cutting Tool Were Machined by Adjusting the Main Parameters of Electrical Discharge Machining (EDM). after the Machining, the Phases Were Analyzed by X-Ray Diffraction Analyzer and the Surface Layer Microstructure Were Observed by Scanning Electronic Microscope. the Fundamental Component of Machined PCD Cutting Tool Affected Layer Was Obtained and the Reason of Bring Affected Layer Was Analyzed. the Relationship Curves between Pulse Width, Working Electric Current and Depth Affected Layer, Surface Roughness Were Summarized. the Relationship between PCD Cutting Tools that Was Machined by EDM and Cutting Tool Flank Width, Workpiece Surface Roughness Were Analyed.The Results Showed that to Adjust Electical Discharge Machining Parameter, such as Pulse Width and Machining Electric Currents, Can Reduce the Depth of Affect Layer and Extend the Service Life of PCD Cutting Tool.These Researches Provide Valuable Test Reference for Drawing up Electrical Discharge Machining Technics of PCD Cutting Tool and Cutting Tool’s Life.

A Truing Technique of Flattening Diamond Grains for Fabricating Microstructures with Fine Surfaces

2008 ◽  
Vol 389-390 ◽  
pp. 350-355
Author(s):  
Takeshi Harada ◽  
Takuya Semba
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Diamond Tool ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
Mesh Size ◽  
Diamond Disk ◽  
Working Surface ◽  
Work Material ◽  
Tool Profile

A truing technique that can be used to shape the tip of an electroformed diamond tool into a hemisphere and flatten diamond grains on the tool working surface at the same level as the bond face was developed. A polycrystalline diamond disk whose top surface roughened by electrical discharge machining was partially flattened by grinding was used as a truer. Diamond grains on the tool working surface were successfully flattened along the hemispherical tool profile when the grains mesh size of #1000 was employed. In addition, a grinding test using glasslike carbon as a work material revealed that a surface roughness of less than 50 nm Rz could be obtained in both cases when moving the tool on contour and scanning paths.

Analysis of Roughness and Heat Affected Zone of Steel Plates Obtained by Laser Cutting

2014 ◽  
Vol 974 ◽  
pp. 169-173 ◽  
Author(s):  
Imed Miraoui ◽  
Mohamed Boujelbene ◽  
Emin Bayraktar
Keyword(s):  
Surface Roughness ◽  
Laser Beam ◽  
Heat Affected Zone ◽  
Laser Power ◽  
Laser Cutting ◽  
Major Effect ◽  
Steel Plates ◽  
Beam Diameter ◽  
Laser Beam Diameter ◽  
Cut Surface

In the present study, high-power CO2 laser cutting of steel plates has been investigated and the effect of the input laser cutting parameters on the cut surface quality is analyzed. The average roughness of the cut surface of the specimens, produced by different laser beam diameter and laser power, were measured by using roughness tester. The scanning electron microscopy SEM is used to record possible metallurgical alterations on the cut edge. The aim of this work is to investigate the effect of laser beam diameter and laser power on the cut surface roughness and on the heat affected zone width HAZ of steel plates obtained by CO2 laser cutting. An overall optimization was applied to find out the optimal cutting setting that would improve the cut surface quality. It was found that laser beam diameter has a negligible effect on surface roughness but laser power had major effect on roughness. The cut surface roughness decreases as laser power increases. Improved surface roughness can be obtained at higher laser power. Also, laser beam diameter and laser power had major effect on HAZ width. It increases as laser power increases.

scholarly journals Surface Finish and Back-Wall Dross Behavior during the Fiber Laser Cutting of AZ31 Magnesium Alloy

Micromachines ◽  
2018 ◽  
Vol 9 (10) ◽  
pp. 485
Author(s):  
Erika García-López ◽  
Juansethi Ibarra-Medina ◽  
Hector Siller ◽  
Jan Lammel-Lindemann ◽  
Ciro Rodriguez
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Fiber Laser ◽  
Pulse Energy ◽  
Laser Cutting ◽  
Experimental Models ◽  
Az31 Magnesium Alloy ◽  
Quadratic Model ◽  
Back Wall ◽  
Argon Gas

Magnesium alloys are of increasing interest in the medical industry due to their biodegradability properties and better mechanical properties as compared to biodegradable polymers. Fiber laser cutting of AZ31 magnesium alloy tubes was carried out to study the effect of cutting conditions on wall surface roughness and back-wall dross. During the experiments, an argon gas chamber was adapted in order to avoid material reactivity with oxygen and thus better control the part quality. A surface response methodology was applied to identify the significance of pulse overlapping and pulse energy. Our results indicate minimum values of surface roughness (Ra < 0.7 μm) when the spot overlapping is higher than 50%. A back-wall dross range of 0.24% to 0.94% was established. In addition, a reduction in back-wall dross accumulations was obtained after blowing away the dross particles from inside the tube using an argon gas jet, reaching values of 0.21%. Laser cutting experimental models show a quadratic model for back-wall dross related with the interaction of the pulse energy, and a linear model dependent on pulse overlapping factor for surface roughness.

scholarly journals Rapid Prototyping of Art Sculptural Shapes According to the Sample

2019 ◽  
Vol 44 (1) ◽  
pp. 27-33 ◽  
Author(s):  
Saša Živanović ◽  
Slobodan Tabaković ◽  
Saša Radjelović
Keyword(s):  
Laser Beam ◽  
Fiber Laser ◽  
Laser Cutting ◽  
Visual Inspection ◽  
Cutting Speed ◽  
Base Material ◽  
Thermal Cutting ◽  
Materials Used ◽  
Cut Surface

The main objective of the research covered in this paper is to present results for the quality of surfaces thermally cut with a laser beam. The variety of steel materials used as samples on which laser cutting is performed are the following Č.0146 (1.0330), Č.0147 (1.0333), Č.2131 (1.5024), SS Ferbec CR, HARDOX 450 and HARDOX 550. Thermal cutting is carried out with a CNC controlled Fiber laser BAYKAL type BLS–F–1530. The quality of the cut surface is analyzed based on varying the power of the laser beam, changing cutting speed and the type of additional gas (oxygen, air and nitrogen). By visual inspection, measuring the roughness of the cut surface and measuring the width of the intersection, it is determined the influence of the factors like type of the base material, type of gases, the power of thelaser beam and the cutting speed, in accordance with the standards DIN EN ISO 9013-2002 and the JUS C.T3.022.

scholarly journals Experimental Study on Micro-Grinding of Ceramics for Micro-Structuring

2021 ◽  
Vol 11 (17) ◽  
pp. 8119
Author(s):  
Yung Na ◽  
Ui Seok Lee ◽  
Bo Hyun Kim
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Bottom Surface ◽  
Depth Of Cut ◽  
Generator Circuit ◽  
Machining Of Ceramics ◽  
Micro Tools

In this study, micro-grinding was performed to investigate the machining characteristics of alumina and zirconia. The machining of ceramics remains highly challenging owing to their properties, such as high brittleness and wear resistance, which leads to a shorter tool life and high machining costs. Polycrystalline diamond (PCD) was selected as the tool material, as it is suitable for machining hard and brittle materials, and micro-electrical discharge machining (EDM) was used to fabricate PCD micro-tools. When using a resistor-capacitor generator circuit in micro-EDM, the discharging energy is related to the working capacitance, and by controlling the working capacitance, the different edge radii and the surface roughness of the tool can be easily achieved. The feed rate, depth of cut, and rotation speed were set as experimental parameters to investigate the grinding characteristics of the ceramics. During the experiment, the grinding force and roughness of the bottom surface were monitored, and the roughness of the machined surfaces was measured using a three-dimensional surface profiler. A working capacitance of 1000 pF was used to fabricate a tool with an edge radius of 3.5 µm. The lower radius of the tool edge resulted in a decrease of the cutting force by 50% at most and a surface roughness of 19 nm Ra.

Dry WEDM in Improving LS-WEDMed Surface Quality

2008 ◽  
Vol 53-54 ◽  
pp. 387-392 ◽  
Author(s):  
Tong Wang ◽  
Yu Mei Lu ◽  
Shu Qiang Xie ◽  
Shuang Shuang Hao ◽  
H. Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Dry Wedm ◽  
Cut Surface ◽  
Discharge Gap

Utilizing gas as the dielectric instead of dielectric liquid has enabled the development of dry wire electrical discharge machining (dry WEDM) technology for finishing cut. Experiment results showed that Low-Speed WEDM (LS-WEDM) in gas offers advantages such as better straightness, and shorter discharge gap. This paper studies on influence of different gas dielectrics, wire winding speed and pulse duration on the WEDMed surface quality (discharge gap, straightness, surface roughness, removal rate) in finishing. New attempt of applying dry WEDM as the 4th cut had been proved feasible in improving conventional multiple cut surface quality of LS-WEDM.

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