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Ultrasonic elliptical vibration cutting is a very promising technique for the machining of brittle materials. However, its machining performance is currently limited by the ductile machining model and the machining strategy with a constant feed rate, leading to low machining efficiency. To overcome this defect, this paper presents a novel self-tuned ultrasonic elliptical vibration cutting (SUEVC) technique to achieve high-efficient ductile-regime machining of the micro-optics array on brittle materials. The proposed SUEVC includes a ductile-regime machining model and a tool path generation method. In SUEVC, the feed rate adaptively changes with respect to the local shape variation of the desired surface along the feeding direction to ensure both crack-free surface and high machining efficiency. Finally, two 1 × 3 spherical micro-optics arrays were successfully fabricated on single-crystal MgF2 by SUEVC and the traditional machining strategy respectively. Results demonstrated that the SUEVC could enhance the machining efficiency by 30% relative to the traditional machining strategy, while maintaining similar surface roughness and a crack-free surface. 相似文献
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机械加工的超精密化和加工机械的微型化 总被引:1,自引:0,他引:1
论述精密加工技术的两个主要研究方向,即机械加工的超精密化和加工机械的微型化的技术现状和发展方向,并介绍国外超精密加工的新方法和加工机械微型化的新技术。 相似文献
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In this paper we present an experimental study on ultraprecision machining (UPM) of single crystal Ge using the μ-LAM process. The material is oriented with the cutting plane normal to the <111> direction. It is shown that increased hydrostatic pressures on the surface during cutting by increasing the tool radius and negative rake angle can aid in enhancing ductile material removal from the surface. It is shown that the cutting performance can be increased by approximately 400% using the optimal tool geometry. It is also shown that the optimal tooling geometry with a steep negative rake angle, i.e. −65°, is capable of producing repeatable surface form and finish over long cutting distances. Finally, it will be shown that the laser beam used for μ-LAM, with the right amount of power, produces surfaces that are under less post machining residual stresses. 相似文献
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N.V. Novikov O.A. Rozenberg S.V. Sokhan A.G. Mamalis 《The International Journal of Advanced Manufacturing Technology》2005,25(3-4):244-247
In the present paper reported is the manufacturing of ceramic spherical implants for medical purposes by employing diamond-abrasive lapping techniques. The technological parameters of this technique and a theoretical model experimentally verified are presented. A novel method of control of the free lapping process is suggested, resulting, as indicated by the experimental and theoretical results, in a decrease of time requested for the coordination of the profiles of the tool and the workpiece and in an increase of the process efficiency when manufacturing precision work surfaces. 相似文献
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Fresnel lenses are gaining wider applications in optoelectronics and photonic devices. They have been evolved into arrays of individual elements with better performance and better capabilities. These arrays may also be realized with individual elements having polygonal shapes such as rectangular, hexagonal, etc to achieve a high fill factor. Due to the fact that the polygonal Fresnel lens arrays are not rotationally symmetrical, they are manufactured by using expensive lithography techniques or time consuming method of having multiple molds assembled together. This paper presents an automated 4-axis ultraprecision machining technique for manufacturing an array of hexagonal Fresnel lenses. In the proposed method, a diamond tool moves as a fixed point on a circle rolling inside a fixed circle which is analogous to a Guilloche machine. The proposed automated machining technique has been experimentally verified through successful manufacturing hexagonal Fresnel lens array in a single process, without having separated sections assembled as a single master mold. From the results, an excellent surface finish and good profile accuracy are also achieved. The developed automated Guilloche machining technique also paves the way for the promising challenges to remove manufacturing barriers of machining freeform surfaces with complex curvatures. 相似文献
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AbstractThis article studies the tribochemical machining of polycrystalline diamond (PCD) by utilizing ferrous tool material as the cutter. The influence of cutting parameters and different ferrous materials on the material removal rate of the PCD workpiece has been investigated. The material removal rate increases with the increase of the rpm of ferrous “cutter”, AISI 1020 steel is unable realize the tribochemical machining, and the material removal rate of using AISI 1045 steel was higher than that of using W2-21/2 steel, e.g. when rpm was 3000, the material removal rate of using AISI 1045 was 0.059?mm/min, and using W2-21/2 it was 0.020?mm/min. The surface roughness of the machined PCD workpiece using W2-21/2 (0.40?μm) was slightly improved in comparison to that produced using AISI 1045 (0.47?μm). The influence of hydrogen catalysis on tribochemical machining of PCD has been investigated. Compared with no use of steam, if a large amount of steam is continuously injected the material removal rate will significantly increase, e.g. when the rpm was 3000 (using AISI 1045) the material removal rate of no steam was 0.059?mm/min, while with steam it was 0.082?mm/min. 相似文献
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揭示了微小孔加工的主要技术难点,论述了国内、外特种加工技术加工微小孔的研究与应用,围绕采用各种特殊方式对微小孔加工的关键技术及适用范围进行了论述。最后,指出了目前微小孔加工技术中有待进一步解决的问题和研究方向。 相似文献
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为充分利用高速切削加工实践中积累的成功经验和数据,提出了运用基于实例推理方法的解决方式。研究了高速切削加工实例的表示方法及实例相似度的性质,将实例的局部相似度分为数值型、无关型、枚举型和依赖型4类,并给出了每种类型的局部相似度的计算方法及实例整体相似度复合算法的计算公式。应用结果表明,所提出的实例及其相似度计算方法是可行的。 相似文献
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Micro ultrasonic machining (micro-USM) is an unconventional micromachining technology that has capability to fabricate high aspect ratio micro-holes, intricate shapes and features on various hard and brittle materials. The material removal in USM is based on brittle fracture of work materials. The mechanical properties and fracture behaviour are different for varied hard and brittle materials, which would make a big difference in the processing capability of micro-USM. To study the processing capability of USM and exploit its potential, the material removal of work materials, wear of abrasive particles and wear of machining tools in USM of three typical hard and brittle materials including float glass, alumina, and silicon carbide were investigated in this work. Both smoothed particle hydrodynamics (SPH) simulations and verification experiments were conducted. The material removal rate is found to decrease in the order of glass, alumina, and silicon carbide, which can be well explained by the simulation results that cracking of glass is faster and larger compared to the other materials. Correspondingly, the tool wear rate also dropped significantly thanks to the faster material removal, and a formation of concavity on the tool tip center due to intensive wear was prevented. The SPH model is proved useful for studying USM of different hard and brittle materials, and capable of predicting the machining performance. 相似文献
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Ultrasonic vibration is assumed to be stable or unchangeable during the process of rotary ultrasonic machining (RUM) on brittle materials, neglecting the effects of different processing parameters. However, no experimental evidence has been reported to validate this assumption. In this study, the effect of thermomechanical load on the stability of ultrasonic amplitude during RUM was investigated by theoretical analysis and experimental procedures on quartz glass and sapphire. It was shown that the instability of ultrasonic amplitude during the machining process is mainly attributed to variation of resonant frequency under the implementation of thermomechanical load. The thermal effects of ultrasonic vibration decrease the resonant frequency of the ultrasonic machine, while mechanical loading during the machining process increases the resonant frequency. Furthermore, a higher feed rate or a harder material leads to a higher resonant frequency change. The variation of ultrasonic power can be used to review the validity of difference-neglected assumption when different values of processing variables, materials, or even machine tools are used during modeling. The results of this study should be well considered for future references when designing an ultrasonic machine. 相似文献
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Russian Engineering Research - 相似文献
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Brittle material removal fraction (BRF) is defined as the area fraction of brittle material removed on machined surface. In the present study, a novel theoretical model of BRF was proposed based on indentation profile caused by intersecting of lateral cracks. The proposed model is related to surface roughness and the subsurface damage (SSD) depth of optical glass during precision grinding. To investigate the indentation profile, indentation tests of K9 optical glass were conducted using single random-shape diamond grains. The experimental results indicate that the indentation profile is an exponent function. To verify the proposed BRF model, BRF, surface roughness and SSD depth of K9 optical glasses were investigated by a series of grinding experiments with different cutting depths. The experimental results show that BRF is dependent on surface roughness and SSD depth. The relationship between BRF, surface roughness and SSD depth is in good accordance with the proposed theoretical model. The proposed BRF model is a reasonable approach for estimating surface roughness and SSD depth during precision grinding of optical glass. 相似文献