scholarly journals Experimental Study on Surface Integrity and Subsurface Damage of Fused Silica in Ultra-Precision Grinding

2021 ◽  
Author(s):  
Yaoyu Zhong ◽  
Yifan Dai ◽  
Hang Xiao ◽  
Feng Shi
Keyword(s):  
Surface Roughness ◽  
Plastic Flow ◽  
Material Removal ◽  
Cutting Speed ◽  
Fused Silica ◽  
Subsurface Damage ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Precision Grinding ◽  
Ultra Precision

Abstract To realize low-damage ultra-precision grinding on fused silica, the surface quality and subsurface damage (SSD) distribution with fine-grained grinding wheel under different depth-of-cut and cutting speed are experimentally studied. The material removal mechanism under different grinding parameters is revealed by calculating undeformed chip thickness and observed with the help of transmission electron microscopy. The results show that brittle-ductile surfaces and ductile-like surfaces are generated during grinding. With the decrease of depth-of-cut and the increase of wheel cutting speed, the ultra-precision grinding changes to ductile-regime grinding with plastic flow removal. Besides, the surface roughness (SR) and SSD depth are reduced. The fracture defects such as fractured pits and grinding streaks on brittle-ductile surface gradually decrease. Instead, a ductile-like surface covered with grinding streaks is found. On brittle-ductile surfaces, the nonlinear relationship SSD∝SR4/3 is no longer proper under the influence of plastic flow. Using surface roughness Ra to predict SSD depth is more accurate. When depth-of-cut is 1 µm, cutting speed is 23.4 m/s and the material removal mode is dominated by plastic flow removal, the surface Ra is improved to 2.0 nm and there is no crack but only a 3.4 nm deep plastic flow layer in subsurface after grinding.

Surface Layer Damage of Quartz Glass Induced by Ultra-Precision Grinding with Different Grit Size

2017 ◽  
Vol 872 ◽  
pp. 19-24
Author(s):  
Zong Chao Geng ◽  
Shang Gao ◽  
Ren Ke Kang ◽  
Zhi Gang Dong
Keyword(s):  
Surface Roughness ◽  
Quartz Glass ◽  
Subsurface Damage ◽  
Grinding Wheel ◽  
Precision Grinding ◽  
Diamond Grinding Wheel ◽  
Diamond Grinding ◽  
Roughness Surface ◽  
Ultra Precision ◽  
Damage Depth

Quartz glass is a typical hard and brittle material. During the manufacturing process of quartz glass components, ultra-precision grinding is widely used due to its high throughput and good dimensional accuracies. However, grinding will unavoidably induce large surface and subsurface damage. In this study, the surface and subsurface damage characteristics of quartz glass substrates ground by diamond wheels with different grit sizes were investigated in terms of surface roughness, surface topography, subsurface microcrack characteristic, and subsurface damage depth. Discussion was also provided to explore corresponding reasons of surface and subsurface damage induced by diamond grinding wheels with different grit sizes of #1500 and #2000. The experiment results showed that the surface roughness, surface damage, and subsurface damage depth induced by #2000 quartz glass was ground by #1500 diamond grinding wheel, and in ductile mode when ground by #2000 diamond grinding wheel.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Thermal Analysis of Laser Irradiation of Fused Silica

2011 ◽  
Vol 314-316 ◽  
pp. 1960-1964 ◽  
Author(s):  
Peng Yao ◽  
Ya Dong Gong ◽  
Suo Xian Yuan ◽  
Tian Feng Zhou ◽  
Ji Wang Yan ◽  
...  
Keyword(s):  
Thermal Analysis ◽  
Surface Roughness ◽  
Laser Irradiation ◽  
Fused Silica ◽  
Maximum Temperature ◽  
Precision Grinding ◽  
Micro Cracks ◽  
Ductile Mode ◽  
Ultra Precision ◽  
Simulation Results

To grind fused silica in ductile mode, surface and subsurface micro cracks (SSMC) on ground fused silica should be repaired by CO2 laser irradiation before ultra-precision grinding. In this paper, 2D thermal analysis of single pass laser irradiation of fused silica was conducted, and the simulation results were discussed by comparing with the experiment results. To repair SSMC and decrease the surface roughness of ground fused silica simultaneously, the maximum temperature on the surface during laser irradiation should be controlled higher than 3280 K and lower than 3550 K.

Optimising the Process Conditions in Ultra-Precision Grinding to Achieve Surface Finish of Optical Quality

2006 ◽  
Vol 304-305 ◽  
pp. 8-13 ◽  
Author(s):  
T. Jin ◽  
D.J. Stephenson
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Optical Quality ◽  
Process Conditions ◽  
Low Alloy Steel ◽  
Optical Surface ◽  
Precision Grinding ◽  
Ultra Precision

Optical surface finish below Ra 10nm can be achieved on a ‘Tetraform C’ grinder of ultra-high stiffness, when grinding a low alloy steel with or without the help of ELID (electrolytic in process dressing). Surface roughness generation modelling has been carried out to predict thepossible surface roughness values. Efforts have been made to transfer the process knowledge to different grinding mode using a rigid 5-axis Edgetek CNC grinder. The effects of material removal rate and grit size and also that of spark out passes on the surface roughness generated have been investigated.

Optimization of tungsten carbide processing parameters for laser heating and ultrasonic vibration composite assisted cutting

2018 ◽  
Vol 233 (12) ◽  
pp. 4140-4153
Author(s):  
Feng Jiao ◽  
Ming-jun Zhang ◽  
Ying Niu
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Ultrasonic Vibration ◽  
Laser Heating ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Properties

Laser heating assisted cutting is a lucrative technique for machining difficult-to-machine materials such as tungsten carbide (YG20), which uses a high power laser to focally heat a workpiece before the material removal with traditional or innovative cutting tool. In the latter case, the application of ultrasonic vibration to the cutting edge was found to replace the continuous cutting mode to the interrupted one, it reduces the adhesion and entanglement of chips, improves the tool wear and surface roughness of the workpiece. The combination of laser heating assisted cutting and two-dimensional ultrasonic vibration cutting methods has been successfully applied by the authors of this paper for cutting of tungsten carbide (YG20). In this follow-up study, the proposed composite method is experimentally and theoretically verified. Through the mathematical model and simulation analysis, its advantages, including small cutting force, softening the effect and improved machining properties of the processed material (YG20) are corroborated. The dependencies between the laser power, cutting speed, depth of cut, and feed rate on the surface roughness are established via the response surface methodology. The genetic algorithm is applied to the optimization of machining parameters by setting the material removal rate as the object variable and surface roughness as a constraint variable. The results obtained strongly suggest that the optimized parameters improve the processing efficiency and furnish the required processing quality.

The Research of ELID Grinding Effect and Surface Quality on Carbonized Cold-Rolled Steel

2012 ◽  
Vol 229-231 ◽  
pp. 542-546
Author(s):  
J.L. Guan ◽  
Li Li Zhu ◽  
H.W. Lu ◽  
Zhi Wei Wang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Grinding Wheel ◽  
Rolled Steel ◽  
Precision Grinding ◽  
Cold Rolled Steel ◽  
Elid Grinding ◽  
Peripheral Velocity ◽  
Ultra Precision ◽  
Cold Rolled

In this document, the electrolytic in-process dressing ( ELID ) grinding technique is used for ultra-precision processing experimental research on the carbonized cold-rolled steel (HRC60～80).A surface roughness of Ra6～8nm was obtained after ELID precision grinding. The results proved that adopting micro grain size (W1.5～W36) and high hardness cast iron based diamond grinding wheel, increasing the wheel peripheral velocity (18～20m/s) and reducing grinding depth can effectively improve surface quality and bring the surface roughness down. The wheel peripheral velocity, grinding depth as well as grinding fluid are the main factors during ultra-precision grinding.

Investigation of Grinding Characteristics of Cemented Carbides YL10.2 and YF06

2014 ◽  
Vol 1017 ◽  
pp. 104-108 ◽  
Author(s):  
Tao Xu ◽  
Jian Wu Yu ◽  
Zhong Jian Zhang ◽  
Jian Gang Tu ◽  
Xiang Zhong Liu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Ground Surface ◽  
Grinding Force ◽  
Cemented Carbides ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Machined Surface ◽  
Ultrafine Grained ◽  
Machined Surface Roughness

YL10.2 and YF06 are ultrafine-grained cemented carbides, and grinding experiments were carried out with resin-bonded diamond grinding wheel. Based on measured grinding force, surface roughness and SEM topography, experimental results were analyzed; grinding forces and depth of grinding approach linear correlation; and the grinding force of YF06 is greater than that of YL10.2 in rough grinding, but the grinding force increases significantly if depth of cut is greater than a certain value in finish grinding. The trend of machined surface roughness looks like “V” type with the increasing of depth of cut; the material removal behavior of ultrafine-grained cemented carbides in grinding was observed; the ploughing and fragmentation exist simultaneously on the ground surface, and the dominated material removal behavior depends on the grinding parameters or chemical composition of workpiece.

Research on ELID Ultra-Precision Grinding Performance of SiCp/Al Composites

2014 ◽  
Vol 614 ◽  
pp. 75-78
Author(s):  
Jia Liang Guan ◽  
Lei Zhu ◽  
Ling Chen ◽  
Xin Qiang Ma ◽  
Xiao Hui Zhang
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Rotation Speed ◽  
Grinding Wheel ◽  
Feed Speed ◽  
Precision Grinding ◽  
Machined Surface ◽  
Elid Grinding ◽  
Machined Surface Roughness ◽  
Ultra Precision

The electrolytic in-process dressing (ELID) grinding technology was adopted for ultra-precision grinding experiments of SiCp/Al composites; the machined surface roughness can obtain Ra0.030μm. The experiments show that: with the grinding wheel rotation speed of 1500r/min, the grinding depth of 0.1μm, and feed speed of 2m/min and using W5 cast iron bonded diamond grinding wheel, the grinding effect can achieve optimal.

Sign in / Sign up

Export Citation Format

Share Document