Applying Constant Pressure Unit to Ductile Mode Cutting of Hard and Brittle Materials

2013 ◽  
Vol 7 (3) ◽  
pp. 278-284 ◽  
Author(s):  
Kunitaka Kuriyama ◽  
◽  
Masahiko Fukuta ◽  
Katsuhiko Sekiya ◽  
Keiji Yamada ◽  
...  
Keyword(s):  
Cutting Forces ◽  
High Efficiency ◽  
Static Pressure ◽  
Constant Pressure ◽  
Brittle Materials ◽  
Ductile Mode ◽  
Hard And Brittle Materials ◽  
Ductile Mode Cutting ◽  
Pressure Unit ◽  
Increasing Demand

It is strongly wished that hard and brittle materials could be used in a wide variety of fields because of their great material characteristics. For now, however, minute profiling or high-efficiency cutting of these materials has not yet been put into practice due to their hardness. At the same time, there have been numerous reports available on ductile mode cutting for hard and brittle materials in response to the increasing demand. Very smoothly finished surfaces can reportedly be generated through the work of a material removal mechanism similar to plastic deformation, done by microminiaturizing cutting units with the sharp cutting edges of tools. Because of the extremely narrow ductile mode regions, however, forced cutting processing, which includes cutting work, demands extremely high motion performance or rigidity of machine tools, and this makes it difficult to realize stable ductile mode cutting. On the other hand, pressure cutting processing similar to polishing is known to be capable of producing extremely smooth finished surfaces on hard and brittle materials; this suggests that we could realize stable ductile mode cutting that will always create the same depths of cut by controlling the insertion forces on the tools. In this paper, in order to realize stable ductile mode cutting, we have devised and prototyped a constant pressure cutting device which can regulate cutting forces by regulating supply pressure with air static pressure bearings. We have investigated the relationships between the pressure supplied in the cutting direction and the cutting forces in order to get static pressure characteristics of the prototype device. We have also carried out experiments to cut hard and brittle materials with the prototype constant pressure cutting device mounted on the tool post of an ultraprecision machine tool to prove the effectiveness of the constant pressure cutting device for the ductile mode cutting of hard and brittle materials.

Ultraprecision Cutting of Glass BK7

2006 ◽  
Vol 315-316 ◽  
pp. 536-540 ◽  
Author(s):  
Ming Zhou ◽  
X.D. Liu ◽  
S.N. Huang
Keyword(s):  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Wear Mechanism ◽  
Optical Glass ◽  
Brittle Materials ◽  
Optical Quality ◽  
Diamond Cutting ◽  
Ductile Mode ◽  
Tool Wear Mechanism ◽  
Ductile Mode Cutting

The development of the capability to machine glass materials to optical quality is highly desirable. In this work, the deformation characteristics of brittle materials were analyzed by micro and nano indentations. Diamond cutting of optical glass BK7 was performed in order to investigate the tool wear mechanism in machining of brittle materials and the effect of tool vibration on material removal mechanism. The tool wear mechanism was discussed on the basis of the observation of wear zone. Ductile-mode cutting has easily been achieved with the application of ultrasonic vibration during cutting of glass. It was confirmed experimentally that the tool wear and surface finish were improved significantly by applying ultrasonic vibration to the cutting tool.

Electroless Plating of Micro Pencil Grinding Tools with 5-10 μm Sized cBN Grits

2016 ◽  
Vol 1140 ◽  
pp. 133-140 ◽  
Author(s):  
Peter Arrabiyeh ◽  
Vandeet Raval ◽  
Benjamin Kirsch ◽  
Martin Bohley ◽  
Jan Christian Aurich
Keyword(s):  
Electroless Plating ◽  
Cutting Forces ◽  
Brittle Materials ◽  
Small Scale ◽  
Experimental Setup ◽  
Micro Machining ◽  
High Quality ◽  
Hard And Brittle Materials ◽  
Scale Structures ◽  
Small Scale Structures

Micro grinding is a promising process to produce small scale structures in hard and brittle materials. Just like macro grinding processes, a high number of abrasive grits embedded on the grinding tools, are applied. This high number of grits results in low cutting forces on individuall grits and very small chip thicknesses, thus generating surfaces with a high quality. The manufacturing of the tools needed to produce such small structures is very challenging. In this paper, a method for the coating of micro pencil grinding tools (MPGTs) is proposed. MPGTs utilize coated superabrasive grits for micro machining hard and hardened materials. The MPGTs developed in the research presented here consist of a base body made of cemented carbide, abrasive grits made of cBN and a nickel bond. The experimental setup and the coating parameters needed to produce a 50-55 μm MPGT with 5-10 μm cBN grits nominal diameter is outlined. In addition, the tools are validated by machining a 500 μm long groove on a hardened 16MnCr5 workpiece.

scholarly journals An Improved Cutting Force Model for Ultrasonically Assisted Grinding of Hard and Brittle Materials

2021 ◽  
Vol 11 (9) ◽  
pp. 3888
Author(s):  
Renke Kang ◽  
Jinting Liu ◽  
Zhigang Dong ◽  
Feifei Zheng ◽  
Yan Bao ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Experimental Studies ◽  
Brittle Materials ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Force Model ◽  
Cutting Force Model ◽  
Fillet Radius ◽  
Hard And Brittle Materials

Cutting force is one of the most important factors in the ultrasonically assisted grinding (UAG) of hard and brittle materials. Many theoretical and experimental studies show that UAG can effectively reduce cutting forces. The existing models for UAG mostly assume an ideal grinding wheel with abrasives in both the end and lateral faces to accomplish material removal, whereas the important role of the transition fillet surface is ignored. In this study, a theoretical cutting force model is presented to predict cutting forces with the consideration of the diamond abrasives in the end face, the lateral face, and the transition fillet surface of the grinding tool. This study analyzed and calculated the vibration amplitudes and the cutting forces in both the normal and tangential directions. It discusses the influences of the input parameters (rotation speed, feed rate, amplitude, depth and radius of transition fillet) on cutting forces. The study demonstrates that the fillet radius is an important factor affecting the grinding force. With an increase in fillet radius from 0.2 to 1.2 mm, the grinding force increases by 139.6% in the axial direction and decreases by 70% in the feed direction. The error of the proposed cutting force model is 10.3%, and the experimental results verify the correctness of the force model.

Study on the Ductile-Mode Milling of Brittle Ceramics

2012 ◽  
Vol 490-495 ◽  
pp. 3654-3657
Author(s):  
Xiang Cheng ◽  
Bin Gao ◽  
Jun Ying Liu ◽  
Xian Hai Yang
Keyword(s):  
Experimental Study ◽  
Brittle Materials ◽  
Ceramic Materials ◽  
High Accuracy ◽  
Experimental Results ◽  
Machining Parameters ◽  
Machining Conditions ◽  
Ductile Mode ◽  
Hard And Brittle Materials ◽  
Experimental Background

Hard and brittle materials such as silicon and ceramic materials are difficult to machining due to their brittle properties. By the ductile-mode machining, delicate features with high accuracy can be created on these materials by mechanical micro/nano machining. This paper introduced the experimental study on the ductile-mode milling of ceramics. First, the experimental background and plans have been introduced. Then, on the sub-micron milling center, experimental results show that ductile-mode machining can be achieved. Both machining parameters and machining conditions are very important in order to realize the ductile-mode machining

Custom Micro Tooling for Mechanical Ductile-Mode Micro/Nano Machining of Hard and Brittle Materials

2012 ◽  
Vol 426 ◽  
pp. 20-23
Author(s):  
Xiang Cheng ◽  
Xi Zhang ◽  
J.Y. Liu ◽  
X.H. Yang ◽  
Z.Q. Tian
Keyword(s):  
Three Dimensional ◽  
Brittle Materials ◽  
Single Crystal Silicon ◽  
Crystal Silicon ◽  
Factors Affecting ◽  
Ductile Mode ◽  
Hard And Brittle Materials ◽  
Micro Tooling ◽  
Key Aspects ◽  
Micro Tools

Hard and brittle materials such as WC, SiC, and single crystal silicon or germanium are widely used in die/moulds for very high accuracy glass products, medical devices, and sensors for MEMS. Mechanical ductile-mode micro/nano milling is an effective method to create three dimensional geometries on these materials. One of the key factors affecting successfully ductile-mode machining is micro tooling. Due to limitations of commercially available micro tools, custom micro tooling is brought forward to give an active solution to this issue. This paper is a further study on custom micro tooling by the author, and several aspects associated with custom micro tooling have been discussed. Experimental results show the feasibility and effectiveness of the successful ductile-mode machining of hard and brittle materials by custom micro tooling. At last, this paper summarizes the techniques associated with custom micro tooling and point out the key aspects for further research on custom micro tooling.

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