scholarly journals Machining of Lenticular Lens Silicon Molds with a Combination of Laser Ablation and Diamond Cutting

Micromachines ◽  
2019 ◽  
Vol 10 (4) ◽  
pp. 250 ◽  
Author(s):  
Jide Han ◽  
Lihua Li ◽  
Wingbun Lee
Keyword(s):  
Laser Ablation ◽  
Mold Material ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Performance ◽  
Diamond Cutting ◽  
Crystal Silicon ◽  
Silicon Mold ◽  
Hybrid Machining ◽  
Lenticular Lens

Lenticular lenses are widely used in the three-dimensional display industry. Conventional lenticular lens components are made of plastics that have low thermal stability. An alternative is to use glass to replace plastic as the lenticular lens component material. Single crystal silicon is often used as the mold material in the precision glass molding process. It is, however, difficult to fabricate a lenticular lens silicon mold that has a large feature size compared to the critical depth of cut of silicon. In order to solve the problems of machining lenticular lens silicon molds using the conventional diamond cutting method, such as low machining efficiency and severe tool wear, a hybrid machining method that combined laser ablation and diamond cutting was proposed. A feasibility study was performed to investigate the possibility of using this method to fabricate a lenticular lens silicon mold. The influence of the laser parameters and machining parameters on the machining performance was investigated systematically. The experimental results indicated that this hybrid machining method could be a possible method for manufacturing lenticular lens silicon molds or other similar microstructures.

Optimization of Cutting Parameters for High Speed End Milling of Single Crystal Silicon by Diamond Coated Tools with Compressed Air Blowing Using RSM

2012 ◽  
Vol 576 ◽  
pp. 46-50 ◽  
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
M.D. Arif
Keyword(s):  
Single Crystal ◽  
High Speed ◽  
End Milling ◽  
Single Crystal Silicon ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Crystal Silicon ◽  
Design Expert ◽  
Coated Tools ◽  
Optimization Of Cutting Parameters

This paper presents the thorough experimental analysis on high speed end milling of single crystal silicon using diamond coated tools. Experiments were conducted on CNC milling machine. The design of the experiments was based on the central composite design (CCD) technique of Design Expert software. Response Surface Methodology (RSM) was used to develop mathematical imperial model to establish a correlation between machining parameters (cutting speed, feed and depth of cut) and machined surface roughness in high speed end milling of single crystal silicon using 2mm diameter diamond coated tools. The optimum machining parameters were determined using the optimization tool of Design Expert software based on the desirability function. Finally, confirmation tests were performed to validate the developed model.

Multi Objective Optimization of Cutting Parameters in Machining Cellulose Based Hybrid Composites

2015 ◽  
Vol 761 ◽  
pp. 287-292
Author(s):  
Raja Izamshah ◽  
Zainudin Zuraidah ◽  
Mohd Shahir Kasim ◽  
M. Hadzley ◽  
M. Amran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hybrid Composites ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
Machining Performance ◽  
Machined Surface ◽  
Multi Objective ◽  
Optimization Of Cutting Parameters

Cellulose based hybrid composites are gaining popularity in the growing green communities. With extensive studies and increasing applications for future advancement, the need for an accurate and reliable guidance in machining this type of composites has increased enormously. Smooth and defect free machined surface are always the ultimate objectives. The present work deals with the study of machining parameters (i.e. spindle speed, feed rate and depth of cut) and their effects on machining performance (i.e. surface roughness and delamination) to establish an optimized setup of machining parameters in achieving multi objective machining performance. Cellulose based hybrid composites consist of jute (a bast fiber) and glass fiber embedded in polyester resins. Response Surface Methodology (RSM) using Box-Behnken Design (BBD) was chosen as the design of experiment approach for this study. Based on that experimental approach, 17 experimental runs were conducted. Mathematical model for each response was developed based on the experimental data. Adequacy of the models were analyzed statistically using Analysis of Variance (ANOVA) in determining the significant input variables and possible interactions. The multi objective optimization was performed through numerical optimization, and the predicted results were validated. The agreement between the experimental and selected solution was found to be strong, between 95% to 96%, thus validating the solution as the optimal machining condition. The findings suggest that feed rate was the main factor affecting surface roughness and delamination .

Experimental Investigation of the Machinability of Single Crystal Silicon in Laser-Assisted Diamond Cutting

2020 ◽  
Author(s):  
Jinyang Ke ◽  
Xiao Chen ◽  
Jianguo Zhang ◽  
Changlin Liu ◽  
Guoqing Xu ◽  
...  
Keyword(s):  
Single Crystal ◽  
Surface Quality ◽  
Laser Power ◽  
Single Crystal Silicon ◽  
Depth Of Cut ◽  
Maximum Height ◽  
Critical Depth ◽  
Diamond Cutting ◽  
Crystal Silicon ◽  
Critical Depth Of Cut

Abstract Laser-assisted diamond cutting is a promising process for machining hard and brittle materials. A deep knowledge of material removal mechanism and attainable surface integrity are crucial to the development of this new technique. This paper focuses on the application of laser-assisted diamond cutting to single crystal silicon to investigate key characteristics of this process. The influence of laser power on the ductile machinability of single crystal silicon, in terms of the critical depth of cut for ductile-brittle transition in laser-assisted diamond cutting, is investigated quantitatively using a plunge-cut method. The experimental results reveal that this process can enhance the silicon’s ductility and machinability. The critical depth of cut has been increased by up to 330% with laser assistance, and its degree generally increases with the increase of laser power. The cross-sectional transmission electron microscope observation results indicate that laser-assisted diamond cutting is able to realize the subsurface damage free processing of single crystal silicon. In order to verify the ability of the laser-assisted diamond cutting to improve the surface quality, the face turning tests are also carried out. A significant improvement of surface quality has been obtained by laser-assisted diamond cutting: Sz (maximum height) has been reduced by 85% and Sa (arithmetical mean height) has been reduced by 45%.

The Use of the Taguchi-Grey Based to Optimize High Speed End Milling with Multiple Performance Characteristics

2006 ◽  
Vol 505-507 ◽  
pp. 835-840 ◽  
Author(s):  
Shen Jenn Hwang ◽  
Yunn Lin Hwang ◽  
B.Y. Lee
Keyword(s):  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Speed ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Performance ◽  
Grey Relational Grade ◽  
Grey Relational

This paper presents a new approach for the optimization of the high speed machining (HSM) process with multiple performance characteristics based on the orthogonal array with the grey relational analysis has been studied. Optimal machining parameters can then be determined by the grey relational grade as the performance index. In this study, the machining parameters such as cutting speed, feed rate and axial depth of cut are optimized under the multiple performance characteristics including, tool life, surface roughness, and material removal rate(MMR). As shown experimental results, machining performance in the HSM process can be improved effectively through this approach.

Selecting Significant Process Parameters of ECG Process Using Fuzzy-MCDM Technique

2015 ◽  
Vol 2 (1) ◽  
pp. 38-53 ◽  
Author(s):  
Goutam Kumar Bose
Keyword(s):  
Surface Roughness ◽  
Removal Rate ◽  
Multiple Criteria Decision Making ◽  
Lower Surface ◽  
Substantial Improvement ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Performance ◽  
Grey Relational Grade ◽  
Grey Relational

The present paper highlights selection of significant machining parameters during Electrochemical grinding while machining alumina-aluminum interpenetrating phase composites by MCDM techniques. The conflicting responses like higher material removal rate, lower surface roughness, lower overcut and lower cutting force are ensured simultaneously by a single parametric combination. Control parameters like electrolyte concentration, voltage, depth of cut and electrolyte flow rate have been considered for experimentation. VIKOR is one of the multiple criteria decision making (MCDM) models to determine the reference ranking from a set of alternatives in the presence of conflicting criteria. Finally Grey Relational Analysis is performed to optimize multiple performances in which different levels combinations of the factors are ranked based on grey relational grade. Surface roughness is given more importance than other responses, using Fuzzy Set Theory considering basic objective of the process. It is observed that substantial improvement in machining performance takes place following this technique. The study highlights the effects of different process variables on multiple performances for complex process like ECG.

An Improvised Method of Machinability Evaluation with Predictive Temperature Model for Inconel 625: A Holistic Machinist’s Perspective

2021 ◽  
Vol 18 (2) ◽  
Author(s):  
P. Singh ◽  
C. Padhy
Keyword(s):  
Tool Wear ◽  
High Heat ◽  
Cutting Fluid ◽  
Inconel 625 ◽  
Surface Finishing ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Temperature Model ◽  
Machining Performance ◽  
Conventional Machining

Machinability of any material is defined as how easily it can be machined (cut) and the factors that govern this machinability comprise machining temperature, tool wear, surface roughness, and the shape of the chip. To enhance the machinability of materials, the improvement of these governing factors is a must. In this regards machinability of Nickel alloys is of great concern as they are associated with problems of high heat generation causing tool wear and poor surface finishing, which adds to the product cost. Therefore, this research aims to improve the machinability of Inconel 625 with the use of MQL assisted with h-BN nano cutting fluid. A comparative study of machining performance of h-BN NMQL with dry and MQL conventional conditions is performed. The outcomes of this study establish the superiority of h-BN over dry machining and MQL conventional machining on various machining parameters by reducing both machining temperature and tool wear. The experimental results revealed that the machining with nano h-BN MQL technique reduces the machining tool tip temperature by 25% and 12%, along with the reduction in tool wear by 67% and 47% in comparison with dry and MQL machining. Additionally, this paper also proposes a numerical model for predicting machining tool temperature using machining parameters (speed, feed and depth of cut) during turning of Inconel 625 under nano h-BN MQL technique.

Modeling and Analysis of Cutting Force in Turning of AISI 316L Stainless Steel (SS) under Nano Cutting Environment

2015 ◽  
Vol 766-767 ◽  
pp. 949-955 ◽  
Author(s):  
T. Rajmohan ◽  
S.D. Sathishkumar ◽  
K. Palanikumar ◽  
S. Ranganathan
Keyword(s):  
Stainless Steel ◽  
Feed Rate ◽  
316L Stainless Steel ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi 316L ◽  
Machining Performance ◽  
Aisi 316L Stainless Steel ◽  
Modeling And Analysis ◽  
Machining Operations

Nano Cutting fluids play a significant role in machining operations and impact shop productivity, tool life and quality of work. In the present work, machining performance of AISI 316L Stainless steel (SS) is assessed under nano cutting environment. Experiments are performed by plain turning of 80mm diameter and 300mm long rod of AISI 316L SS on NAGMAT centre lathe under wet machining with and without Multi Wall Carbon nano Tubes (MWCNT) inclusions in the conventional lubricant. The Second order quadratic models were developed to predict cutting forces using response surface methodology (RSM) based D-optimal design. Machining parameters such as speed, feed rate and depth of cut are chosen as numerical factor, and the wt % of MWCNT content is considered as the categorical factor. Furthermore, using analysis of variance method, significant contributions of process parameters have been determined. Experimental results reveal that wt % of MWCNT and feed rate are the dominant variables on responses.

Micro-Machinability Studies of Single Crystal Silicon Using Diamond End-Mill

2016 ◽  
Author(s):  
Zi Jie Choong ◽  
Dehong Huo ◽  
Patrick Degenaar ◽  
Anthony O’Neill
Keyword(s):  
Size Effect ◽  
Single Crystal Silicon ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Crystal Silicon ◽  
Edge Chipping ◽  
Cutting Energy ◽  
Machining Conditions

This paper presents the research on the machinability studies in micro-milling of (001) silicon wafer. Excessive generation of undesirable surface and subsurface damages such as surface edge chipping often occurs when machined at depth of cut of several hundreds of microns. Ideal machining strategy to reduce the generation of edge chipping is required. Investigations on the effect of machining conditions on the cutting performances and size effect on the specific cutting energy in silicon micro-milling were conducted. These investigations provide understandings on the behavior of cutting mechanism during machining and helps to identify suitable machining parameters for fracture free machining using diamond end mills. Full slot milling were performed along <100> and <110> directions on a (001) surface wafer under various machining conditions. Results show that machined surfaces along <100> were of better quality than those along <110> and is in agreement with previous studies. Furthermore, good machining quality was achieved when machined at depth of cut of 10 μm or feed per tooth of 0.075 μm/tooth, regardless of the machining conditions. In addition, investigation for the size effect on specific cutting energy also shows that brittle mode machining begins when feed per tooth increases beyond 0.4 μm/tooth.

Ultra-Precision Cutting of Single Crystal Silicon Using Diamond Tool with Large Top Corner Radius

2012 ◽  
Vol 523-524 ◽  
pp. 81-86 ◽  
Author(s):  
Yuya Kobaru ◽  
Eiji Kondo ◽  
Ryuichi Iwamoto
Keyword(s):  
Single Crystal ◽  
Feed Rate ◽  
Cutting Tools ◽  
Single Crystal Silicon ◽  
Depth Of Cut ◽  
Diamond Cutting ◽  
Crystal Silicon ◽  
Diamond Cutting Tools ◽  
Single Crystal Diamond ◽  
Ultra Precision

A lot of studies on the ultra-precision cutting of single crystal silicon have been reported and they used the single crystal diamond cutting tools having the sharp cutting edge. However, the diamond cutting tools having small chamfer at the cutting edge are usually used in practical machining shops. In addition, studies on the relationship between the tool wear and the machined surface have been reported little although the relationship is important in practical applications. In this study, ultra-precision cutting of single crystal silicon, using cutting fluids, feed rate, and depth of cut as experimental parameters, were carried out by using the single crystal diamond cutting tools having small chamfer and large nose radius, and effects of the cutting fluids, the feed rate, and the depth of cut on the machining accuracy and tool wear were studied. As a result, the optimum cutting conditions was obtained as follows: the cutting fluid was kerosene, the feed rate was 2.0μm/rev, and the depth of cut was 1.0μm.

scholarly journals Molecular Dynamics Investigation of Residual Stress and Surface Roughness of Cerium under Diamond Cutting

Micromachines ◽  
2018 ◽  
Vol 9 (8) ◽  
pp. 386 ◽  
Author(s):  
Yao Li ◽  
Maobing Shuai ◽  
Junjie Zhang ◽  
Haibing Zheng ◽  
Tao Sun ◽  
...  
Keyword(s):  
Molecular Dynamics ◽  
Residual Stress ◽  
Surface Roughness ◽  
Surface Quality ◽  
Depth Of Cut ◽  
Formation Mechanisms ◽  
Machining Parameters ◽  
Diamond Cutting ◽  
Machined Surface ◽  
Machined Surface Quality

Machined surface quality in terms of residual stress and surface roughness has an important influence on the performance of devices and components. In the present work, we elucidate the formation mechanisms of residual stress and surface roughness of single crystalline cerium under ultraprecision diamond cutting by means of molecular dynamics simulations. Influences of machining parameters, such as the rake angle of a cutting tool, depth of cut, and crystal orientation of the workpiece on the machined surface quality were also investigated. Simulation results revealed that dislocation activity and lattice distortion are the two parallel factors that govern the formation of both residual stress and surface roughness. It was found that both distributions of residual stress and surface roughness of machined surface are significantly affected by machining parameters. The optimum machining parameters for achieving high machined surface quality of cerium by diamond cutting are revealed.

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