Ultraprecision Ductile-Regime Cutting of Optical Glass

2007 ◽  
Vol 364-366 ◽  
pp. 69-73 ◽  
Author(s):  
Ming Zhou ◽  
Ying Chun Liang ◽  
Shao Nan Huang
Keyword(s):  
Tool Wear ◽  
Optical Glass ◽  
Cutting Process ◽  
Process Conditions ◽  
Diamond Cutting ◽  
Machined Surface ◽  
Vibration Cutting ◽  
Tool Wear Mechanism ◽  
Cutting Zone ◽  
Zone Microstructure

Nano-indentation of glass SF11 was performed for understanding the material deformation behavior in practical cutting process. Diamond cutting tests under different process conditions, i.e. conventional turning and ultrasonic vibration assisted cutting, were also carried out. Cleavage and microchipping appear to be the dominant tool wear mechanism based on the analytical results of wear zone microstructure and machined surface topography. The change in the tribology of the cutting process as well as the alteration of the deformation mechanism of the work material in the cutting zone might be responsible for the reduction in tool wear in vibration cutting.

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.

An Experimental Study on Diamond Cutting of Optical Glass

2008 ◽  
Vol 375-376 ◽  
pp. 211-215 ◽  
Author(s):  
Hang Zhao ◽  
Ming Zhou
Keyword(s):  
Experimental Study ◽  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Optical Glass ◽  
High Hardness ◽  
Optical Quality ◽  
Process Conditions ◽  
Machined Surface ◽  
Ductile Mode ◽  
Indentation Analysis

Optical glass is one of the most difficult-to-cut brittle materials due to its high brittleness and high hardness. In this work, an experimental study was conducted to diamond-cut glass SF6 in ductile mode. Nano-indentation analysis was performed for understanding the material deformation behavior in practical cutting process. The effect of process conditions, i.e. conventional turning and ultrasonic vibration assisted cutting, on the tool wear and surface quality was discussed based on the observations of the tool wear zone microstructure and the machined surface topography. The investigation presents the feasibility of achieving optical quality surfaces on glass with the application of ultrasonic vibration cutting technology. The tool life and surface finish were improved significantly by applying ultrasonic vibration to the cutting tool.

2D FEM Estimate of Tool Wear in Hard Cutting Operation: Tool Wear and Simulation of Hard Cutting Process under Steady State

2009 ◽  
Vol 69-70 ◽  
pp. 306-310
Author(s):  
Fu Gang Yan ◽  
Cai Xu Yue ◽  
Xian Li Liu ◽  
Yu Fu Li ◽  
Shu Yi Ji
Keyword(s):  
Steady State ◽  
Tool Wear ◽  
Model Simulation ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Workpiece Material ◽  
Machined Surface ◽  
Fem Model ◽  
Fem Method ◽  
Hard Cutting

Tool wear plays an important role in cutting process research. It affects the quality of machined surface and cutting parameter to a great extent, such as cutting force, cutting temperature and cutting quiver. In order to predict tool wear in hard cutting process by using FEM method, the character of tool wear during cutting process is presented firstly, and Usui’s tool wear rate model is introduced. Then the FEM model for steady state cutting process using Abaqus is established. FEM model describes the workpiece material characteristic accurately for the process of PCBN tool cutting GCr15 by adoptiving Johnson-Cook constitutive model. Simulation results of steady cutting process offer foundation to simulate tool wear.

Machinability of the EBM Ti6Al4V in Cryogenic Turning

2015 ◽  
Vol 651-653 ◽  
pp. 1183-1188 ◽  
Author(s):  
Stefano Sartori ◽  
Alberto Bordin ◽  
Stefania Bruschi ◽  
Andrea Ghiotti
Keyword(s):  
Tool Wear ◽  
Liquid Nitrogen ◽  
Surface Integrity ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Fluid ◽  
Cobalt Chromium ◽  
Machined Surface ◽  
Surgical Implants ◽  
Cutting Zone

In machining operations, the adoption of a cutting fluid is necessary to mitigate the effects of the high temperatures generated on the cutting zone, and, therefore, to avoid severe detrimental effects on the tool wear and surface integrity. In the biomedical field, the traditional processes to manufacture surgical implants made of Titanium and Cobalt Chromium Molybdenum alloys involve turning and milling operations. To cool the cutting tool with standard oil emulsions leaves contaminants on the machined surfaces, which require further cleaning steps that are expensive in terms of time and costs. Currently, this limitation is marginally overcome by machining without the coolant; however, as a consequence, severe tool wear and poor surface integrity take place. In the last years, many studies have been conducted on the application of Liquid Nitrogen as a coolant in machining difficult-to-cut materials such as Ti6Al4V. Thanks to its properties to evaporate immediately when getting in contact with the cutting zone, thus living the workpiece and chips dry and clean other than its ability to lower the cutting temperature. The adoption of Liquid Nitrogen as a cooling mean in machining surgical implants may represent an optimum solution enhancing the benefits of dry machining. This work is aimed at evaluating the performances of the Liquid Nitrogen as a coolant in semi-finishing turning of Ti6Al4V produced by Electron Beam Melting, a comparison with dry turning is presented. The alloy machinability in such conditions is evaluated in terms of tool wear, machined surface integrity and chip morphology.

scholarly journals Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4664
Author(s):  
Yao Sun ◽  
Liya Jin ◽  
Yadong Gong ◽  
Yang Qi ◽  
Huan Zhang ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Tool Wear ◽  
Rear Surface ◽  
Cutting Process ◽  
Cutting Fluid ◽  
Machined Surface ◽  
Micro Cutting ◽  
Cutting Surface ◽  
Alloy Material ◽  
End Mills

Aluminum alloy material is widely used in the electronics, weapons, aviation and aerospace industries, due to its medium strength, good corrosion resistance, good toughness and excellent oxidation properties. With the trend of product miniaturization, micro cutting has become the mainstream technique for fabricating micro parts and components, so it is very meaningful and vital to work on removing the cutting fluid from the micro cutting process and make it totally sustainable and eco-friendly. In this work, an attempt has been made to fabricate micro textures onto the rear surface of helical micro end mills with diameters of less than 1 mm. Micro textures in the form of grooves were fabricated using a noncontact low speed wire electrical discharge turning technique. Dry micro cutting experiments were carried out on an aluminum alloy material using helical micro end mills with micro textures and the dry micro cutting surface quality and tool wear have been investigated. The influence of dry micro cutting parameters on the surface roughness parameters were also investigated. Experimental results showed that the Sa and Sq can be reduced to be about 1.56 μm and 2.08 μm, respectively. Contrasting results indicate that the implantation of micro textures does not deteriorate the dry micro cutting surface but improves the machined surface consistency of an aluminum alloy workpiece. The tool wear on helical micro end mills with micro textures involved in the dry micro cutting process of Al 6061 mainly include rear frictional wear, oxidation wear and diffusion wear.

Tool wear and surface finish in diamond cutting of optical glass

2006 ◽  
Vol 174 (1-3) ◽  
pp. 29-33 ◽  
Author(s):  
Ming Zhou ◽  
B.K.A. Ngoi ◽  
M.N. Yusoff ◽  
X.J. Wang
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Optical Glass ◽  
Diamond Cutting

Identification of Subsurface Deformation in Machining of Inconel 718

2011 ◽  
Vol 117-119 ◽  
pp. 1681-1688 ◽  
Author(s):  
Jin Ming Zhou ◽  
Volodymr Bushlya ◽  
Ru Lin Peng ◽  
Jan Eric Stahl
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Strain Analysis ◽  
Cutting Parameters ◽  
Correct Prediction ◽  
Process Conditions ◽  
Machined Surface ◽  
Subsurface Deformation ◽  
Subsurface Region

There is considerable industrial significance to understand the nature of subsurface deformation under the machined surface for correct prediction of surface properties in machined components based upon the machined conditions and material behaviors that give rise to them. In this study, high speed machining of Inconel 718 was carried with whisker reinforced ceramic cutting tool under different conditions of tool wear, coolant state and cutting parameters. The objective of the present investigation was to determine the effect of both cutting parameters and tool wear on the plastic deformation in the subsurface region of Inconel 718 after the finishing machining with above process conditions. The surface and subsurface region of machined specimens were examined using a high resolution scan electron microscope (HRSEM) and EBSD technique, microhardness measurements were also conducted on the test samples, accordingly plastic strain analysis were carried out.

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