scholarly journals Atomistic and Experimental Investigation of the Effect of Depth of Cut on Diamond Cutting of Cerium

Micromachines ◽  
2018 ◽  
Vol 9 (1) ◽  
pp. 26 ◽  
Author(s):  
Junjie Zhang ◽  
Maobing Shuai ◽  
Haibing Zheng ◽  
Yao Li ◽  
Ming Jin ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Depth Of Cut ◽  
Diamond Cutting

Ultraprecision Ductile-Regime Cutting of Brittle Materials

2007 ◽  
Vol 339 ◽  
pp. 395-399 ◽  
Author(s):  
Ming Zhou ◽  
X.D. Liu ◽  
S.N. Huang
Keyword(s):  
Ultrasonic Vibration ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Diamond Cutting ◽  
Vibration Cutting ◽  
Ductile Regime Machining ◽  
Critical Depth Of Cut ◽  
Micro Deformation ◽  
Micro Indentation

Soda-lime glass is a typical brittle material, which is difficult to realize ductile-regime machining by using conventional cutting technology due to the extremely small critical depth of cut. In this work, the micro-deformation characteristics of this kind of materials were analyzed by micro indentation. Ultrasonic vibration assisted diamond cutting was performed in order to investigate the effect of tool vibration on material removal process and surface quality. The profiles of cut surfaces were measured and compared with those obtained by conventional diamond cutting. Real depths of cut in ultrasonic vibration cutting correspond well with the nominal ones. The change in the tribology of the cutting process as well as the alteration of the deformation mechanism of the work material might be responsible for the reduction in tool wear in vibration cutting.

Single Point Diamond Turning of Silicon by Using Micro-Laser Assisted Machining Technique

2014 ◽  
Author(s):  
Hossein Mohammadi ◽  
H. Bogac Poyraz ◽  
Deepak Ravindra ◽  
John A. Patten
Keyword(s):  
Fiber Laser ◽  
Cutting Tool ◽  
Single Point ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Beam Diameter ◽  
Diamond Cutting ◽  
Laser Assisted Machining ◽  
Diamond Cutting Tool ◽  
Si Wafer

In this study, single point diamond turning (SPDT) is coupled with the micro-laser assisted machining (μ-LAM) technique. The μ-LAM system is used to preferentially heat and thermally soften the work piece material in contact with a diamond cutting tool. In μ-LAM the laser and cutting tool are integrated into a single package, i.e. the laser energy is delivered by a single mode fiber laser to and through a diamond cutting tool. This hybrid method can potentially increase the critical depth of cut (DoC), i.e., a larger ductile-to-brittle transition (DBT) depth, in ductile regime machining, resulting in a higher material removal rate (MRR). An IR continuous wave (CW) fiber laser, wavelength of 1064nm and max power of 100W with a beam diameter of 10μm, is used in this investigation. In the current study SPDT tests were employed on single crystal silicon (Si) wafer which is very brittle and hard to machine by conventional methods. Different outputs such as surface roughness and depth of cut for different set of experiments were analyzed. Results show that an unpolished surface of a Si wafer can be machined in one pass to get a very good surface finish. The Ra was brought down from 1.2μm to 275nm only in one pass which is a very promising result for machining the Si wafer.

Research on the Influence of Cutting Fluids on the Critical Depth of Cut in Diamond Cutting of Optical Glass BK7

2010 ◽  
Vol 431-432 ◽  
pp. 126-129 ◽  
Author(s):  
Ming Zhou ◽  
Peng Jia ◽  
Min Li
Keyword(s):  
Boric Acid ◽  
Optical Glass ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Critical Depth ◽  
Diamond Cutting ◽  
Brittle Ductile Transition ◽  
Fluid Properties ◽  
Critical Depth Of Cut

In diamond cutting of optical glasses, the magnitude of critical depth of cut for brittle-ductile transition is an important factor affecting the machinability of the work material in terms of production rate and surface quality. In this work, scratching tests with increasing depths of cut were conducted on glass BK7 to evaluate the influence of the cutting fluid properties on the critical depth of cut. Boric acid solutions of different concentrations were selected as cutting fluids in the tests. The resulting scratches were examined utilizing a white light interferometer and the values of the critical depth of cut were determined based on the observations of the micro-morphology of the scratch surfaces produced. Experimental results indicated that compared with the process without cutting fluid action, the critical depth of cut in diamond cutting of glass BK7 can be increased by using boric acid solution as the cutting fluid.

Experimental Investigation on High-Speed Milling of Aluminum Alloys

2011 ◽  
Vol 418-420 ◽  
pp. 1141-1147
Author(s):  
Yong Liu ◽  
Li Tang Zhang ◽  
Zhi Hong Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Experimental Investigation ◽  
Aluminum Alloys ◽  
High Speed ◽  
Depth Of Cut ◽  
Processing Temperature ◽  
Single Factor ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling is recognized as one of rapidly development machining methods. The article gives details of machining experiments with different aluminum alloys. Through a lot of single factor experiments and the orthogonal multi-factor experiments, and also use method of semi-artificial thermocouple. This paper mainly studies influence of surface roughness and residual stress with changed rotate speed, tooth load and radial depth of cut, and changed law of processing temperature for rotate speed. Though experiments shows that enhancing rotate speed may reduce surface roughness and residual stress within certain limits and the result of experiments is not agree with Carl Salomon’s theory.

Indentation and Scratching Experimental Research on Brittle-Ductile Transition of Optical Glass SF6

2013 ◽  
Vol 589-590 ◽  
pp. 480-484 ◽  
Author(s):  
Peng Jia
Keyword(s):  
Boric Acid ◽  
Optical Glass ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Critical Depth ◽  
Diamond Cutting ◽  
Brittle Ductile Transition ◽  
Fluid Properties ◽  
Critical Depth Of Cut ◽  
Micro Morphology

In diamond cutting of optical glasses, the magnitude of critical depth of cut for brittle-ductile transition is an important factor affecting the machinability of the work material in terms of production rate and surface quality. In this work, scratching tests with increasing depths of cut were conducted on glass BK7 to evaluate the influence of the cutting fluid properties on the critical depth of cut. Boric acid solutions of different concentrations were selected as cutting fluids in the tests. The resulting scratches were examined utilizing a white light interferometer and the values of the critical depth of cut were determined based on the observations of the micro-morphology of the scratch surfaces produced. Experimental results indicated that compared with the process without cutting fluid action, the critical depth of cut in diamond cutting of glass BK7 can be increased by using boric acid solution as the cutting fluid.

scholarly journals Development of an End-Toothed Disc-Based Quick-Change Fixture for Ultra-Precision Diamond Cutting

Machines ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 257
Author(s):  
Xuesen Zhao ◽  
Xiangwu Cui ◽  
Zhenjiang Hu ◽  
Qiang Zhang ◽  
Tao Sun
Keyword(s):  
Finite Element ◽  
High Precision ◽  
High Efficiency ◽  
Small Diameter ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Diamond Cutting ◽  
Positioning Accuracy ◽  
Small Depth ◽  
Ultra Precision

With its standardized and unified interface, the quick-change fixture is an important part for maintaining high efficiency without compensation of precision in the metal-turning process because it can conveniently realize high-precision repeated clamping and multi-station conversion without complex positioning and adjustment steps. However, the existing quick-change fixture products and related research cannot fully meet the needs of repeatability and applicability raised from ultra-precision, single-point diamond turning with ultra-high accuracy and ultra-small depth of cut. In this paper, we develop a quick-change fixture for ultra-precision diamond turning, in which the end-toothed disc acts as the positioning element. Specifically, the main parameters of two key components of the end-toothed disc and slotted disc spring are calculated analytically to ensure the positioning accuracy of the designed fixture used in the rotation condition, which is further ensured by controlling the machining tolerance of the tooth profile of the end-toothed disc. Additionally, finite element simulations are performed to investigate the static and modal states of the quick-change fixture, which demonstrate a maximum deformation of about 0.9 μm and a minimum natural frequency of 5655.9 Hz for the designed fixture. Two high-precision sensors are used to detect the radial jump and end run-out values after repeated clamping actions, which are employed to verify the repetitive positioning accuracy of the fixture. Subsequent finite-element simulation of the clamping of small-diameter copper bar, as well as the diamond turning experiment, jointly demonstrate that the designed fixture can achieve a precision of 1 μm. Current work provides an effective quick-change fixture to reduce the deformation of a weak-stiffness workpiece caused by clamping deformation in ultra-precision diamond cutting.

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%.

Mathematical Model of the Diamond-Bit Drilling Process and Its Practical Application

1982 ◽  
Vol 22 (06) ◽  
pp. 911-922 ◽  
Author(s):  
Malgorzata B. Ziaja ◽  
Stefan Miska
Keyword(s):  
Penetration Rate ◽  
Drilling Fluid ◽  
Active Surface ◽  
Rock Properties ◽  
Depth Of Cut ◽  
Drilling Process ◽  
Diamond Cutting ◽  
Rate Of Penetration ◽  
Drilling Performance ◽  
Diamond Bit

Abstract With several limiting assumptions, a mathematical model of the diamond-bit drilling, process has been developed. The model represented by an instantaneous rate-of-penetration equation takes into account the reduction in penetration rate during drilling resulting from bit wear. The model has been tested both under laboratory and under field conditions. The comparison of the theoretical and experimental results has shown reasonable agreement. A method for estimating rock properties also has been established. Using this method, we can find the so-called index of rock strength and the index of rock abrasiveness. Introduction Several published studies concerned with diamond-bit drilling report on rock properties and drillability. drilling fluid additives, diamond wear, and drilling performance theories. Among the factors, that affect diamond-bit drilling performance, the type of formation to be drilled is of utmost importance since it significantly affects the type of bit, the drilling practices. and subsequently the rate of penetration and the drilling cost. The nature of the formation is also one of the main factors in planning deep wells, fracture jobs, mud and cement technologies, etc. For rock properties evaluation as well as for selection of proper drilling practices, several descriptions of the diamond-bit drilling process have been developed. The relevant literature is extensive and is not reviewed in this paper. The objective of this paper is to describe the diamondbit drilling model for surface-set diamond core bits and its application to determining the index of formation strength and the index of formation abrasiveness. The main difference between our model and the models known in literature is that we consider the effect of friction between the diamond cutting surfaces and the rock. A decrease in penetration rate is observed if the drilling parameters, are constant and if the formation is macroscopohomogeneous. Drilling Model The drilling model for a surface-set diamond core bit is subjected to the following limiting assumptions.Rock behavior during cutting with a single diamond may be approximated by a rigid Coulomb plastic material.The active surface of the bit is flat, and diamonds are spherical with diameter. d.The cross-sectional area of the chip formed by a single diamond is equal to the diamond cutting surface and can be established by geometry.During drilling, the neighboring diamonds work together to make a uniform depth of cut (Fig. 1).A number of diamonds forming one equivalent blade have to provide it uniform depth of cut from the inner to the outer diameter of the diamond core bit. so the bit is modeled to be a combination of several equivalent blades (Fig. 2).The diamond distribution technique provides uniform radial coverage that results in equally loaded cutting diamonds.Individual cutting diamonds perform some work that results from the friction between the rock and the diamond.Bit wear is assumed to be gradual while drilling is in progress. Under the preceding assumptions we may state that the drilling rate of the surface-set diamond core bit is a function only of weight on bit (WOB), rotary speed, average density of the diamonds on the bit's active surface, diamond size, core-bit diameters, rock properties, and degree of diamond dullness. The effects of flow rate, differential pressure, hydraulic lift, drilling fluid properties. and drillstring dynamics are ignored. According to Peterson, the penetration rate of the diamond bit, after some modifications, can be described by the following simplified equation. (1) This equation does not include the effect of diamond wear and hence pertains to unworn bits or to when bit dullness is negligible. SPEJ P. 911^

Tool Wear in Diamond Cutting Sinusoidal Microstructured Surfaces

2010 ◽  
Vol 431-432 ◽  
pp. 94-97
Author(s):  
Hai Jun Zhang ◽  
Ming Zhou
Keyword(s):  
Tool Wear ◽  
Diamond Turning ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Diamond Cutting ◽  
Microstructured Surfaces ◽  
Sharp Point ◽  
High Feed ◽  
Catastrophic Fracture

Tool wear in diamond cutting sinusoidal mircostructured surfaces may be quite different from that in conventional diamond turning as the sharp point tip tool is used and the depth of cut changes cyclically along the profile of the cutting surfaces. In present paper, the diamond tool geometry requirements for cutting sinusoidal microstructured surfaces were analyzed. A series of controlled cutting tests of LY12 were executed on a 2-aixs bench type ultra-precision turning machine which equipped a fast tool servo (FTS). Tool wear patterns were investigated with varied feed speed in diamond cutting sinusoidal microstructured surfaces. The scanning electron microscope (SEM) examination results of tool wear showed that the visible wear was occurred after a short cutting distance. The gradual wear around tool tip and along cutting edges was predominant wear pattern with a low feed speed. The catastrophic fracture wear at tool tip was happened with a high feed speed and the wear of sharp point tip of tool was more serious than that of cutting edges of tool.

scholarly journals Enhancing the AWJ Cutting Performance by Multipass Machining with Controlled Nozzle Oscillation

2005 ◽  
Vol 291-292 ◽  
pp. 453-458 ◽  
Author(s):  
Jun Wang ◽  
S. Xu
Keyword(s):  
Experimental Investigation ◽  
Alumina Ceramic ◽  
Cutting Performance ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Application Domain ◽  
Process Variables ◽  
Geometrical Features ◽  
Cutting Capacity ◽  
Awj Cutting

The cutting performance in abrasive waterjet (AWJ) multipass cutting with and without controlled nozzle oscillation is presented based on an experimental investigation cutting an 87% alumina ceramic. The cutting capacity in terms of the depth of cut and the kerf geometrical features is analyzed with respect to the process variables. It is found that multipass cutting is a viable means to increase the cutting performance and application domain of this technology, while a further increase in the cutting performance can be made by using a controlled nozzle oscillation technique.

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