scholarly journals Micro Defects on Diamond Tool Cutting Edge Affecting the Ductile-Mode Machining of KDP Crystal

Micromachines ◽  
2020 ◽  
Vol 11 (12) ◽  
pp. 1102
Author(s):  
Shuo Zhang ◽  
Wenjun Zong
Keyword(s):  
Hydrostatic Pressure ◽  
Cutting Edge ◽  
Dihydrogen Phosphate ◽  
Kdp Crystal ◽  
Tool Edge ◽  
Blunt Edge ◽  
Flat Edge ◽  
Tool Cutting ◽  
Diamond Cutting Tool

As a soft-brittle material, the machined surface quality of potassium dihydrogen phosphate (KDP) crystal is heavily affected by the edge quality of the diamond cutting tool. However, nanoscale micro defects inevitably occur on the freshly sharpened tool edge, and the machining mechanism for KDP crystal remains unclear. Therefore, in this work, three types of tool-edge micro defects are classified according to their cross-sections, including the blunt-edge, crescent-edge, and flat-edge micro defects. Moreover, the smoothed particle hydrodynamics (SPH) method is employed to reveal the material removal mechanism of KDP crystal with consideration of different tool-edge micro defects, and the flat-edge micro defects are subdivided into flat edge A (similar to flank wear) and flat edge B (similar to chamfered edge) on the basis of their effects in machining. The simulation results indicate that the surfaces machined by crescent edge and flat edge A are unsmooth with large-size defects due to the disappearance of hydrostatic pressure beneath the cutting edge. As for the blunt edge and flat edge B, the machined surfaces are smooth with a favorable increment of hydrostatic pressure for processing brittle materials, which indicates that a solution to eliminate the tool-edge micro defects is necessary, e.g., the passivation method. For keeping the cutting edge as sharp as possible in removing the tool-edge micro defects completely by passivation, the effect of tool shank depression angles on the geometries of the passivated cutting edge is investigated, and a high-quality cutting edge with a micro chamfered edge is obtained after passivation at a depression angle of 60° and re-sharpening of the rake face. Finally, the tool cutting performance after passivation is validated through fly-cutting experiments of KDP crystal. The chamfered edge can produce the best defect-free surface with the minimum surface roughness.

Edge Design for Regrinding Cutting Tool

2011 ◽  
Vol 101-102 ◽  
pp. 938-941
Author(s):  
Xin Li Tian ◽  
Hao Wang ◽  
Xiu Jian Tang ◽  
Zhao Li ◽  
Ai Bing Yu
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Edge Angle ◽  
Edge Radius ◽  
Tool Edge ◽  
Edge Defects ◽  
Tool Cutting ◽  
Edge Preparation

Regrinding of wasted cutting tools can recycle resources and decrease manufacturing costs. Influence of relative tool sharpness and tool cutting edge angle on tool edge radius were analyzed. Cutting force and cutting temperature were simulated with FEM on different edge radius. Edge preparation experiments were carried out though an abrasive nylon brushing method. The results show that RTS and cutting edge angle have influence on edge radius. Small edge radius might result in small cutting forces and lower average temperatures, could maintain the cutting state between tool and workpiece. The cutting edge defects can be eliminated through edge preparation, and a smooth cutting edge can be obtained. Cutting tool life will be improved through proper edge design and edge preparation.

Influence of Edge Preparation Parameters on the Cutting Edge in Drag Finishing

2016 ◽  
Vol 693 ◽  
pp. 1067-1073 ◽  
Author(s):  
Xue Feng Zhao ◽  
Lin He ◽  
Sen Yuan ◽  
Wei Juan Zheng
Keyword(s):  
Cutting Edge ◽  
Workpiece Surface ◽  
Orthogonal Experiments ◽  
Spindle Rotation ◽  
Tool Edge ◽  
Milling Tool ◽  
The Stability ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can eliminate defects and realize hone cutting edge, which can improve the quality of the workpiece surface, elevate the stability of cutting process and the tool life. In order to better investigate the edge preparation mechanism, the influence law of the edge preparation process parameters on the cutting edge is analyzed. The paper presents the single factor experiments and orthogonal experiments with the cemented carbide milling tool spindle rotation rate, edge preparation time, abrasive size and abrasive ratio in drag finishing. The edge preparation mechanism is revealed in the paper, which provides basis for the structure optimization of cutting edge contour.

Experimental Researches on Precision Grinding of KDP Crystal

2007 ◽  
Vol 359-360 ◽  
pp. 113-117 ◽  
Author(s):  
Qiang Guo Wang ◽  
Hang Gao ◽  
Quan Zhong Zhang ◽  
Xian Suo Cao ◽  
Ren Ke Kang
Keyword(s):  
Potassium Dihydrogen Phosphate ◽  
Dihydrogen Phosphate ◽  
Precision Grinding ◽  
Machine Material ◽  
Kdp Crystal ◽  
Potassium Dihydrogen ◽  
Surface Damages ◽  
Feeding Speed ◽  
Experimental Researches

The KDP (Potassium Dihydrogen Phosphate) crystal, used as an important photoelectron part in the laser nuclear fusion system, is a typical kind of hard-to-machine material because of its soft, brittle, anisotropic property and nano-scale requirement for the shape and plane precision. Based on the experiments of the KDP crystal’s grindability, certain process parameters, such as the wheel granularity, the grinding depth and the workpiece’s feeding speed etc., and their influences on the grinding force and the surface roughness of KDP workpiece are analyzed. Furthermore, some KDP crystal’s typical surface damages in grinding are analyzed and some technical approaches to increasing the ultraprecision machining surface quality of KDP crystal are suggested as well.

Influence of Grinding to the Surface and Subsurface Quality of KDP Crystal

2008 ◽  
Vol 53-54 ◽  
pp. 203-208 ◽  
Author(s):  
Dong Jiang Wu ◽  
B. Wang ◽  
Hang Gao ◽  
Ren Ke Kang ◽  
Xian Suo Cao
Keyword(s):  
Feed Rate ◽  
Removal Rate ◽  
Optical Microscope ◽  
Subsurface Damage ◽  
Machining Process ◽  
Grinding Wheel ◽  
Dihydrogen Phosphate ◽  
Machining Time ◽  
Kdp Crystal

Potassium dihydrogen phosphate (KDP) crystal is widely used in navigates spaceflight, national defenses, energy sources and information technology fields based on its excellent nonlinear optical property. Surface quality of KDP crystal influences the property and life time of the device directly. So detection and analysis of the damage induced during machining process, especially on subsurface, should be solved. In this paper, surface damage of the KDP crystal, which machined from #600 grinding wheel with different feed rate, was detected by optical microscope. Cross section and selective etching were used to analyzing the subsurface damage. Because #600 grinding wheel mainly used in coarse grinding and the removal rate is high, the results shown that there was obvious scratch, crack and crushing on the machining surface. When the feed rate is 10+m and 40+m, the subsurface damage depth is 7.41+m and 8.96+m corresponding. This study is a kind of guide for following precision grinding, polishing machining time and removal amount.

Experimental Study on Micro-Deliquescence Ultra-Precision Polishing with Fine Water Mist for KDP Crystal

2013 ◽  
Vol 797 ◽  
pp. 423-427 ◽  
Author(s):  
Xu Wang ◽  
Hang Gao ◽  
Dong Ming Guo ◽  
Y.C. Chen ◽  
C.P. Song
Keyword(s):  
Experimental Study ◽  
Potassium Dihydrogen Phosphate ◽  
Water Mist ◽  
Precision Machining ◽  
Dihydrogen Phosphate ◽  
Kdp Crystal ◽  
Potassium Dihydrogen ◽  
Ultra Precision ◽  
Polishing Tool

KDP crystal (Potassium dihydrogen phosphate single crystal) is extremely difficult to obtain flawless surface because of its soft, brittle, and hygroscopic. And a large amount of time has been spend on obtaining flawless surface with ultra-precision machining methods. In order to quickly reduce surface roughness on KDP crystal, a new micro-deliquescence polishing method with fine water mist was proposed, the polishing tool with fine water mist was designed, and the polishing experiment was carried out. The micro-deliquescence polishing with fine water mist can improve the surface quality of KDP crystal quickly, so it is an effective preprocessing before ultra-precision machining.

scholarly journals Influence of End Mill Manufacturing on Cutting Edge Quality and Wear Behavior

2021 ◽  
Vol 5 (3) ◽  
pp. 77
Author(s):  
Berend Denkena ◽  
Alexander Krödel-Worbes ◽  
Sascha Beblein ◽  
Markus Hein
Keyword(s):  
Wear Behavior ◽  
Cutting Edge ◽  
End Mills ◽  
Edge Quality ◽  
Manufacturing Process Chain ◽  
The Individual ◽  
Application Specific ◽  
Milling Tools ◽  
Edge Preparation

One of the decisive factors for the performance of milling tools is the quality of the cutting edge. The latter results from the process control of the individual steps along the tool manufacturing process chain, which generally includes the sintering or pressing of the blanks, grinding, cutting edge preparation, and coating of the tools. However, the targeted and application-specific design of the process steps in terms of high economic efficiency is currently limited by a lack of knowledge regarding the influence of the corresponding process parameters on the resulting cutting edge quality. In addition, there is a lack of suitable parameters that adequately represent the characteristics of the cutting edge microtopography. This publication therefore investigates the influence of manufacturing processes on cutting edge quality and wear behavior of end mills. On this basis, different characterization parameters for the cutting edge quality are derived and evaluated with regard to their ability to predict the wear behavior.

scholarly journals 1178 J, 527 nm near diffraction limited laser based on a complete closed-loop adaptive optics controlled off-axis multi-pass amplification laser system

2021 ◽  
Vol 9 ◽  
Author(s):  
Deen Wang ◽  
Xin Zhang ◽  
Wanjun Dai ◽  
Ying Yang ◽  
Xuewei Deng ◽  
...  
Keyword(s):  
Laser Beam ◽  
Adaptive Optics ◽  
Closed Loop ◽  
Focal Spot ◽  
Beam Quality ◽  
Laser System ◽  
Diffraction Limit ◽  
Kdp Crystal ◽  
Main Amplifier

Abstract A 1178 J near diffraction limited 527 nm laser is realized in a complete closed-loop adaptive optics (AO) controlled off-axis multi-pass amplification laser system. Generated from a fiber laser and amplified by the pre-amplifier and the main amplifier, a 1053 nm laser beam with the energy of 1900 J is obtained and converted into a 527 nm laser beam by a KDP crystal with 62% conversion efficiency, 1178 J and beam quality of 7.93 times the diffraction limit (DL). By using a complete closed-loop AO configuration, the static and dynamic wavefront distortions of the laser system are measured and compensated. After correction, the diameter of the circle enclosing 80% energy is improved remarkably from 7.93DL to 1.29DL. The focal spot is highly concentrated and the 1178 J, 527 nm near diffraction limited laser is achieved.

Schneidkantenpräparation von VHM-Mikrofräsern*/Cutting edge preparation of cemented carbide micro milling tools – A comparison of different fine machining processes

2015 ◽  
Vol 105 (11-12) ◽  
pp. 805-811
Author(s):  
E. Uhlmann ◽  
D. Oberschmidt ◽  
A. Löwenstein ◽  
M. Polte ◽  
I. Winker
Keyword(s):  
Tool Wear ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Machining Processes ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Milling Tools ◽  
Edge Preparation

Die Prozesssicherheit beim Mikrofräsen lässt sich mit einer gezielten Schneidkantenverrundung erheblich steigern. Dabei werden durch verschiedene Präparationstechnologien unterschiedliche Geometrien und Einflüsse auf den Fräsprozess erzeugt. Der Fachbeitrag behandelt den Einsatz präparierter Mikrowerkzeuge in Zerspanversuchen, in denen auf die Zerspankräfte, den Verschleiß sowie die Oberflächengüten eingegangen wird.   Process reliability in micro milling can be increased by a defined cutting edge preparation. Different cutting edge preparations cause different effects on tool behavior in the downstream micro milling process. In this paper, the process forces, the tool wear and the surface quality of prepared micro milling tools are characterized in cutting tests.

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