3D characterisation of tool wear whilst diamond turning silicon |
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| Affiliation: | 1. Cranfield University, Cranfield, Bedfordshire, MK43 0AL England, UK;2. Thales Optics, St. Asaph, LL17 OLL Wales, UK;3. Contour Fine Tooling, Wedgwood Court, Stevenage, Hertfordshire, SG1 4QR England, UK;1. Nano-Mechatronics, University of Science &Technology, Daejeon 305-350, Korea;2. Division of Nano-Mechanical Systems, Korea Institute of Machinery and Materials, Daejeon 305-343, Korea;3. National Core Research Center for Hybrid Materials Solution, Pusan National University, Busan 609-735, Korea;1. School of Mechanical and Aerospace Engineering, Queen''s University, Belfast, BT95AH, UK;2. Department of Design, Manufacture and Engineering Management, University of Strathclyde, Glasgow, G11XQ, UK;3. Department of Business Administration, University of Illinois at Urbana-Champaign, USA;4. School of Engineering and Physical Sciences, Heriot-Watt University, Edinburgh, EH144AS, UK;1. Centre for Precision Manufacturing, DMEM, University of Strathclyde, UK;2. School of Engineering, London South Bank University, 103 Borough Road, London SE1 0AA, UK;3. EPSRC Centre for Doctoral Training in Ultra-Precision Engineering, University of Cambridge and Cranfield University, UK;4. School of Aerospace, Transport and Manufacturing, Cranfield University, Bedfordshire MK43 0AL, UK;5. Department of Mechanical Engineering, Shiv Nadar University, Gautam Budh Nagar, 201314, India;6. Center for Precision Engineering, Harbin Institute of Technology, Harbin, PR China;1. Center of Precision Engineering, Harbin Institute of Technology, Harbin, 150001, China;2. Machining and Condition Monitoring Group, Faculty of Engineering, University of Nottingham, NG7 2RD, UK;3. School of Mechanical Engineering, South China University of Technology, Guangzhou, 510640, China;4. School of Mechanical Engineering, Tongji University, 201804, China |
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| Abstract: | Nanometrically smooth infrared silicon optics can be manufactured by the diamond turning process. Due to its relatively low density, silicon is an ideal optical material for weight sensitive infrared (IR) applications. However, rapid diamond tool edge degradation and the effect on the achieved surface have prevented significant exploitation. With the aim of developing a process model to optimise the diamond turning of silicon optics, a series of experimental trials were devised using two ultra-precision diamond turning machines. Single crystal silicon specimens (1 1 1) were repeatedly machined using diamond tools of the same specification until the onset of surface brittle fracture. Two cutting fluids were tested. The cutting forces were monitored and the wear morphology of the tool edge was studied by scanning electron microscopy (SEM).The most significant result showed the performance of one particular tool was consistently superior when compared with other diamond tools of the same specification. This remarkable tool performance resulted in doubling the cutting distance exhibited by the other diamond tools. Another significant result was associated with coolant type. In all cases, tool life was prolonged by as much as 300% by using a specific fluid type.Further testing led to the development of a novel method for assessing the progression of diamond tool wear. In this technique, the diamond tools gradual recession profile is measured by performing a series of plunging cuts. Tool shape changes used in conjunction with flank wear SEM measurements enable the calculation of the volumetric tool wear rate. |
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