Microtexture Generation Using Controlled Chatter Machining in Ultraprecision Diamond Turning

This paper describes a new method of microtexture generation in precision machining through self-excited vibrations of a diamond cutting tool. Conventionally, a cutting tool vibration or chatter is detrimental to the quality of the machined surface. In this study, an attempt is made to use the cutting tool's self-excited vibration during a cutting beneficially to generate microtextures. This approach is named as “controlled chatter machining (CCM).” Modal analysis is first performed to study the dynamic behavior of the cutting tool. Turning processes are then conducted by varying the tool holder length as a means to control vibration. The experimental results indicate that the self-excited diamond cutting tool can generate microtextures of various shapes, which depend on the cutting tool shank, cutting speed, feed, and cutting depth. The potential application of this proposed technique is to create microtextures in microchannels and microcavities to be used in mass and heat transfer applications.

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

Volume 2: Processing ◽

10.1115/msec2014-4138 ◽

2014 ◽

Cited By ~ 1

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.

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Thermal and Structural Deformations During Diamond Turning of Rotationally Symmetric Structured Surfaces

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2951929 ◽

2008 ◽

Vol 130 (4) ◽

Cited By ~ 10

Author(s):

Stefan Rakuff ◽

Paul Beaudet

Keyword(s):

Cutting Tool ◽

Diamond Turning ◽

Machining Process ◽

Diamond Cutting ◽

Structured Surfaces ◽

Optical Films ◽

Single Crystal Diamond ◽

Structural Loop ◽

Diamond Cutting Tool ◽

Aerostatic Spindle

Diamond turning of microstructures on the surface of large cylindrical workpieces has become important with advances made in roll-to-roll manufacturing processes of optical films, drag reduction films, microfluidic devices, and organic electronic components. Micromachined cylindrical workpieces are used as production masters in various printing, embossing, and coating processes. The microstructures machined in this study were 18μm in height and had a pitch of 35μm. These dimensions required control of the location of the single crystal diamond cutting tool that was used for machining to submicrometer levels. The significant error sources identified in the machining process were thermal effects and deflections of the structural loop of the diamond turning machine (DTM) that led to registration errors of the cutting tool between consecutive passes. Environmental temperature variation errors (ETVEs) were measured and modeled as a function of long-term ambient temperature fluctuations. Also studied was the mechanical compliance of the structural loop of the DTM. The height adjustable tool stack and aerostatic spindle were identified as the most compliant components. The cutting forces for radius and V-shaped diamond cutting tools at various depths of cut were measured using the known compliance of the aerostatic bearing to predict workpiece deflections.

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Process Parameter and Cutting-Tool Geometry Study for Precision Face Turning of a Clock Dial

Materials Science Forum ◽

10.4028/www.scientific.net/msf.697-698.125 ◽

2011 ◽

Vol 697-698 ◽

pp. 125-128

Author(s):

Shen Yung Lin ◽

Y.H. Lin ◽

M.S. Hsu

Keyword(s):

Chip Formation ◽

Feed Rate ◽

Cutting Tool ◽

Cutting Speed ◽

Systematic Investigation ◽

Process Parameter ◽

Tool Geometry ◽

Machined Surface ◽

Related Quality

After the processing of a clock dial, the precision dimension and uniform distribution of the tool-trace pattern on the dial surface have a connection with luster image and attractiveness, which in turn would have an impact on the additional values and prices for a clock. Through a systematic investigation among the lathe structure, process parameter and cutting-tool geometry in advance, the total results indicated that the rigidity of the lathe structure and the precision of the slider movements are excellent and they had only a little effect on the surface-related quality for a dial face turning. Hence, the combination of process parameter and cutting-tool angle becomes more essential. End face turning simulation and experiment of a copper alloy were thus conducted in this paper, and the chip formation process and machined surface-related quality are investigated, respectively. The effects of cutting tool geometry and process parameter on the results of chip formation, surface rough, tool-trace pattern and luster uniformity are investigated, and these results are also compared with each other. The results show that when larger clearance and rake angles used in conjunction with a lower feed rate, no matter how much cutting speed was enhanced, the surface-related quality of a dial surface is not good. However, when these two larger angles used combined with a larger feed rate, the quality of a dial surface would slightly be improved. By using smaller clearance and rake angles along with the higher feed rate and cutting speed would obtain a better surface-related quality with uniform luster and attractiveness.

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Effect of Cutting Conditions on Dimensional Accuracy and Surface Roughness in Traditional Milling of Steel

Volume 2: Advanced Manufacturing ◽

10.1115/imece2016-66154 ◽

2016 ◽

Author(s):

Brian Stringer ◽

Rui Liu ◽

Alfonso Fuentes Aznar ◽

Patricia Iglesias

Keyword(s):

Surface Roughness ◽

Cutting Tool ◽

Gear Tooth ◽

Cutting Speed ◽

Dimensional Accuracy ◽

Cutting Conditions ◽

Variable Speed ◽

Machined Surface ◽

Gear Manufacturing

Gear milling is one of the common gear manufacturing processes. In gear milling, the cutting edge of the cutting tool has an identical profile with the profile between gear teeth, and the cutting tool travels along the axial direction of the gear blank to produce the gear tooth by tooth. Due to the high requirements about the dimensional accuracy and the surface roughness during the gear manufacturing process, it is very crucial to understand the influences of cutting conditions on those requirements to improve the quality of the product and increase the production rate. In this study, a machined gear blank made from 1018 cold-rolled steel was subjected to variable speed and feed-rates in a traditional milling operation using a standard gear-milling cutter. The effect of the variable speed and feed-rates were analyzed by measuring the total lead (helix) error, total profile (involute) error, and surface finish of each gear tooth subjected to the variable cutting conditions. The objective is to experimentally investigate the correlation between the cutting conditions, i.e. cutting speed and feed, with the accuracy and quality of the machined surface during the gear milling process.

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UG and VERICUT-Based Processing of Special-Shaped Stone Samples

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.415-417.924 ◽

2011 ◽

Vol 415-417 ◽

pp. 924-928 ◽

Cited By ~ 1

Author(s):

Yu Hou Wu ◽

Qiang Gao ◽

De Hong Zhao

Keyword(s):

Technological Parameter ◽

Cutting Tool ◽

Cutting Parameters ◽

Actual Process ◽

Diamond Cutting ◽

Nc Code ◽

Tool Paths ◽

Horizontal Working ◽

Diamond Cutting Tool

In order to verify the processability of a special-shaped stone machining center’s horizontal working portion, to process complex stone products. On the basis of analysis of the physical characteristics of diamond cutting tool and stone, create a model and use UG software to program, making this machine center’s dedicated post processor. Simulate NC code that is generated with VERICUT software, optimize the cutting parameters and analyse its surface quality. Avoid interference in the program, gouge, collisions and other phenomena by adjusting the tool axis’s attitude and the tool paths. Actual process verified the reliability of the program, technological parameter is rational, quality of the parts’ surface is well. Make precisely outline and tool wear is small, overcome the drawbacks of CNC system, get a higher efficiency.

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Consequence of Orientation on the Single Crystal Diamond Cutting Tool

Progress in Precision Engineering ◽

10.1007/978-3-642-84494-2_74 ◽

1991 ◽

pp. 392-402 ◽

Cited By ~ 2

Author(s):

K. Uegami ◽

K. Tamamura

Keyword(s):

Single Crystal ◽

Cutting Tool ◽

Diamond Cutting ◽

Single Crystal Diamond ◽

Diamond Cutting Tool

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Thermal hardening and calculation of the mathematical model of face milling of parts made of steel 95X18-Sh to improve the quality of the surface layer

10.36652/1813-1336-2021-17-5-200-206 ◽

2021 ◽

pp. 200-206

Author(s):

I.N. Sedinin ◽

V.F. Makarov

Keyword(s):

Mathematical Model ◽

Cutting Speed ◽

Physical And Mechanical Properties ◽

Face Milling ◽

Experiment Planning ◽

Depth Of Cut ◽

Machined Surface ◽

The Mathematical Model ◽

Full Factorial

It is considered the complex of operations of the technological process for the heat treatment of steel 95X18-Sh, as a result of which the material of the samples increases the hardness to 59...61 HRC, and also improves the physical and mechanical properties. A full-scale full factorial experiment of face milling of samples was carried out using the method of mathematical planning. In the experiments, a high-precision machine and a carbide cutting tool were used. To calculate the values of the roughness function, the following are taken as independent variables: cutting speed, feed per tooth and depth of cut. In order to determine the coefficients of the linear equation, a central compositional orthogonal plan of the second order for three factors was used. A matrix of levels of variation of independent variable factors and a matrix of experiment planning were compiled. A regression analysis of the obtained experimental statistical data was carried out using the Microsoft Excel, Statistica and Wolfram Alpha programs. As a result of the calculations, a mathematical model of the roughness of the machined surface and optimal cutting conditions were determined.

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Development and optimization of ultrasonic elliptical vibration cutting device based on single excitation

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4049965 ◽

2021 ◽

pp. 1-29

Author(s):

Sen Yin ◽

Zhigang Dong ◽

Yan Bao ◽

Renke Kang ◽

Wenhao Du ◽

...

Keyword(s):

Cutting Speed ◽

Tungsten Alloy ◽

Asymmetric Structure ◽

Diamond Cutting ◽

Elliptical Vibration Cutting ◽

Vibration Cutting ◽

Elliptical Vibration ◽

Technical Capability ◽

Diamond Cutting Tool ◽

Ultrasonic Elliptical Vibration

Abstract Ultrasonic elliptical vibration cutting (UEVC) technique, as an advanced cutting method, has been successfully applied to machine difficult-to-cut materials for the last decade. In this study, the mechanism of the elliptical vibration locus caused by the “asymmetric structure” of the horn was analyzed theoretically firstly, and the corresponding relationship between the degree of asymmetry and the elliptical vibration locus was determined based on finite element method (FEM). Then an efficient single-excitation UEVC device with “asymmetric structure” was developed and optimized. The resonant frequency of the device was 40.8 kHz, and the amplitude reached 12.4 µm, which effectively broke the limitation of cutting speed in UEVC. Finally, the UEVC device's performance was tested, and the advantages in improving the tungsten alloy surface quality and reducing diamond cutting tool wear validated the technical capability and principle of the proposed device.

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