Development of Slip/fracture Activation Model Based on Force Modeling of Single-Crystal Sapphire During Ultra-Precision Machining

2021 ◽  
Author(s):  
Suk Bum Kwon ◽  
Sangkee Min
2010 ◽  
Vol 645-648 ◽  
pp. 853-856 ◽  
Author(s):  
Wolfgang J. Choyke ◽  
B. D'Urso ◽  
Fei Yan ◽  
Robert P. Devaty

Ultra-precision machining is dominated by single-crystal diamond cutting tools, and is typically applied to a narrow range of materials, particularly aluminum and copper. Single-crystal SiC can be comparable to some diamonds in hardness and thermal conductivity, while potentially having superior chemical and thermal stability, yet it has not been explored as a cutting tool for ultra-precision machining. We made two cutting tools with single-crystal SiC, one with sharp corners and one with a large circular radius, and used them to cut flat surfaces on two materials, 316 stainless steel and nickel. These materials generally cause unacceptably rapid diamond tool wear. We report the average roughness of the resulting surfaces cut with single-crystal 4H and 6H SiC tools.


2021 ◽  
Vol 9 ◽  
Author(s):  
Chengyuan Yao ◽  
Wanfu Shen ◽  
Xiaodong Hu ◽  
Chunguang Hu

The sesquioxide Lu2O3 single crystal has attracted tremendous attention as potential host material for high-power solid-state lasers. As polishing is the terminal process of conventional ultra-precision machining, the quality of polished crystal directly impacts the crucial performance indicators of optics. The high melting point of Lu2O3 single crystal makes crystal preparation difficult. Therefore, investigations on the surface/subsurface quality inspection of polished Lu2O3 single crystal are scarce. In this paper, we utilize the quasi-Brewster angle technique (qBAT) based on ellipsometry to inspect the quality of polished Lu2O3 single crystal, achieving fast, non-destructive, and high-sensitive surface/subsurface damage assessment. A systematic crystal processing scheme is designed and polished Lu2O3 crystal samples are obtained. To verify the results of qBAT, the surface and subsurface quality are tested using optical profilometer and transmission electron microscope, respectively. The consistency of the test results demonstrates the feasibility, high sensitivity, and accuracy of the qBAT. To our knowledge, this is the first time that the qBAT is applied to investigate the polished surface/subsurface quality of Lu2O3 single crystal. In conclusion, this method provides a powerful approach to the high-precision characterization of the surface/subsurface quality of Lu2O3 single crystal, and has significant potential for material property study and process optimization during ultra-precision machining.


2011 ◽  
Vol 138-139 ◽  
pp. 1246-1250
Author(s):  
Ji Cai Kuai

The dynamic minimum thickness of cut for the ultra-precision machining surface quality is important influence. Between tool and the workpiece for the friction coefficient were analysised, the relationship of the friction coefficient and the MTC were discussed, and the MTC and its effects on surface roughness were a theoretical analysised and experimental verification with processed single crystal copper and single crystal aluminum by AFM’s diamond tip. The results show: the MTC of single-crystal copper (single crystal aluminum) is 5.2nm (8.2nm) in stable cutting conditions. Further processing single crystal copper (ingle crystal aluminum) with cutting thickness of 5.2nm (8.2nm), and the surface roughness Ra160nm (Ra110nm) is obtained. So the MTC is evolving with the friction coefficient and the force ratio, theoretical MTC tends to be minimal value then before the adhering effect to reach remarkable. Appropriate adjustments cutting parameters, the cutting process can always micro-cutting phase to reach the steady-thin chip, and no plowing phenomenon. So the surface residues highly were reduced and higher surface quality was achieved.


2011 ◽  
Vol 211 (12) ◽  
pp. 2152-2159 ◽  
Author(s):  
Yilong Wang ◽  
Qingliang Zhao ◽  
Yuanjiang Shang ◽  
Pengxiang Lv ◽  
Bing Guo ◽  
...  

2015 ◽  
Vol 105 (07-08) ◽  
pp. 469-474
Author(s):  
L. Schönemann ◽  
N. Sassi ◽  
R. Krüger ◽  
A. Bloem ◽  
B. Denkena ◽  
...  

Die ultrapräzise Fräsbearbeitung ist eine flexible Möglichkeit, um optische Freiformflächen herzustellen. Aufgrund der hohen Genauigkeitsanforderungen sind die anwendbaren Vorschub- und Schnittgeschwindigkeiten allerdings beschränkt. Deshalb werden hier zwei neue Ansätze zur Wirtschaftlichkeitssteigerung präsentiert: der Einsatz ultrapräziser Magnetführungen sowie die modellbasierte Vorhersage von Bahnabweichungen und deren Kompensation mithilfe der elektromagnetischen Führung (Teil 1: wt 6-2015, S. 366–370).   Ultra-precision milling is a flexible process for generating optical freeform surfaces. However, due to the tight tolerances of such parts, only low feedrates and cutting velocities are applied. This publication presents two novel approaches to increase the productivity of ultra-precision machining: the use of electromagnetic guideways and the model-based prediction of path deviations and their compensation using the electromagnetic guideway.


Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 929
Author(s):  
Xudong Yang ◽  
Zexiao Li ◽  
Linlin Zhu ◽  
Yuchu Dong ◽  
Lei Liu ◽  
...  

Taper-cutting experiments are important means of exploring the nano-cutting mechanisms of hard and brittle materials. Under current cutting conditions, the brittle-ductile transition depth (BDTD) of a material can be obtained through a taper-cutting experiment. However, taper-cutting experiments mostly rely on ultra-precision machining tools, which have a low efficiency and high cost, and it is thus difficult to realize in situ measurements. For taper-cut surfaces, three-dimensional microscopy and two-dimensional image calculation methods are generally used to obtain the BDTDs of materials, which have a great degree of subjectivity, leading to low accuracy. In this paper, an integrated system-processing platform is designed and established in order to realize the processing, measurement, and evaluation of taper-cutting experiments on hard and brittle materials. A spectral confocal sensor is introduced to assist in the assembly and adjustment of the workpiece. This system can directly perform taper-cutting experiments rather than using ultra-precision machining tools, and a small white light interference sensor is integrated for in situ measurement of the three-dimensional topography of the cutting surface. A method for the calculation of BDTD is proposed in order to accurately obtain the BDTDs of materials based on three-dimensional data that are supplemented by two-dimensional images. The results show that the cutting effects of the integrated platform on taper cutting have a strong agreement with the effects of ultra-precision machining tools, thus proving the stability and reliability of the integrated platform. The two-dimensional image measurement results show that the proposed measurement method is accurate and feasible. Finally, microstructure arrays were fabricated on the integrated platform as a typical case of a high-precision application.


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