Reducing the cutting tool wear in diamond turning of Zerodur glass-ceramic by the mechanical cleaning effect of ultrasonic vibration assistance

Chen，Yuhan; Sun，Linhe; Chen，Minghan; Wu，Yongbo

2023-10-27

10.1016/j.jmapro.2023.09.038

Journal of Manufacturing Processes   影响因子和分区

1526-6125

The effects and mechanisms of using ultrasonic vibration assistance (U.V.-assisted machining) combined with straight-nosed cutting tools on reducing the cutting tool wear in single-point diamond turning (SPDT) of Zerodur glass-ceramic are analysed and experimentally investigated. Aiming at the predominant abrasive wear in machining hard and brittle materials, analyses have shown that applying appropriate ultrasonic vibration to the cutting tool can induce considerable inertial acceleration to the wear particles residing on the tool-work interface for promoting their ejection from the contact area to reduce the abrasion. Meanwhile, the high thermal conductivity of diamond can prevent the possible excessive temperature elevation of the cutting tool surface that may result from the in-plane vibration components. To verify these, a longitudinal ultrasonic vibrator that works together with the Poisson's effect was designed for the SPDT processes with straight-nosed cutting tools. Machining tests on Zerodur optics have shown that the assistant ultrasonic vibration is able to decrease the tool flank wearland width by about 30 %, and the groove-like scratches on the tool flank wearland surface were reduced, which is consistent with the analytical deductions. Besides, no significant traces of structural change, element diffusion, and oxidation were found on the worn cutting tool surfaces under either the assisted or unassisted cutting conditions. The experiments have also shown that the enhanced durability of cutting tools has extended the cutting tool life for maintaining good machined surface quality, which is particularly beneficial to the ultra-precision machining of large-size optical parts.

Cutting tool wear Machining performance Single-point diamond turning Surface integrity Ultrasonic vibration-assistance Zerodur glass-ceramic

EI ; SCI

英语

第一 ; 通讯

20233814740495

Cutting tools ; Diamonds ; Glass ceramics ; Particle size analysis ; Thermal conductivity ; Turning ; Ultrasonic effects ; Ultrasonic waves ; Wear of materials

Gems:482.2.1 ; Machine Tool Accessories:603.2 ; Machining Operations:604.2 ; Thermodynamics:641.1 ; Ultrasonic Waves:753.1 ; Physical Properties of Gases, Liquids and Solids:931.2 ; Materials Science:951

2-s2.0-85171307864

Scopus

Department of Mechanical and Energy Engineering,Southern University of Science and Technology,Guangdong,518055,China

Chen，Yuhan,Sun，Linhe,Chen，Minghan,et al. Reducing the cutting tool wear in diamond turning of Zerodur glass-ceramic by the mechanical cleaning effect of ultrasonic vibration assistance[J]. Journal of Manufacturing Processes,2023,104:460-471.

Chen，Yuhan,Sun，Linhe,Chen，Minghan,&Wu，Yongbo.(2023).Reducing the cutting tool wear in diamond turning of Zerodur glass-ceramic by the mechanical cleaning effect of ultrasonic vibration assistance.Journal of Manufacturing Processes,104,460-471.

Chen，Yuhan,et al."Reducing the cutting tool wear in diamond turning of Zerodur glass-ceramic by the mechanical cleaning effect of ultrasonic vibration assistance".Journal of Manufacturing Processes 104(2023):460-471.