Effect of cutting parameters on surface quality during diamond turning of micro-prism array

Wu, Dongxu; Zhang, Peng; Wang, Huiming; Qiao, Zheng; Wang, Bo

doi:10.1177/0954405415625925

Cited by 12 publications

(5 citation statements)

References 20 publications

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“…Cutting quality is the basic guarantee of production quality, which is generally evaluated by the mean peak-to-valley height and average deviation of surface roughness [21]. Wu et al studied the effect of cutting depth on cutting quality when turning a micro-prism array with diamond tools and showed that cutting depth affects surface defects; cutting depths greater than 4 µm further degraded the quality of the machined surface [22].…”

Section: Introductionmentioning

confidence: 99%

Machinability of Stone—Plastic Materials During Diamond Planing

et al. 2019

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This paper investigated the machinability of a stone–plastic composite (SPC) via orthogonal cutting with diamond cutters. The objective was to determine the effect of cutting depth on its machinability, including cutting forces, heat, chip formation, and cutting quality. Increased cutting depth promoted an increase in both frictional and normal forces, and also had a strong influence on the change in normal force. The cutting temperatures of chips and tool edges showed an increasing trend as cutting depth increased. However, the cutting heat was primarily absorbed by chips, with the balance accumulating in the cutting edge. During chip formation, the highest von Mises strain was mainly found in SPC ahead of the cutting edge, and the SPC to be removed partially passed its elastic limit, eventually forming chips with different shapes. Furthermore, the average surface roughness and the mean peak-to-valley height of machined surfaces all positively correlated to an increase in cutting depth. Finally, with an increase in cutting depth, the chip shape changed from tubular, to ribbon, to arc, to segmental, and finally, to helical chips. This evolution in chip shape reduced the fluctuation in cutting force, improving cutting stability and cutting quality.

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Section: Introductionmentioning

confidence: 99%

Machinability of Stone—Plastic Materials During Diamond Planing

et al. 2019

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“…Optimal process parameters for RSA 905 have been identified as having a cutting speed of 1750 rpm, a feed rate of 5 mm/min, a depth of cut of 25 µm, and a surface roughness R a of 3.2 nm [5]. By comparison, process parameters for the diamond turning of polycarbonate have been identified to be 800-4000 rpm, 0.5-4 µm/rev, a depth of 2 µm [33], and for aluminium alloy 6061, reported values are 500-3000 rpm, 5-25 mm/min, a depth of 2-20 µm [34], and for micro grooving of copper, 6-300 rpm, and for feed dependent on thread pitch, a depth of 1-18 µm [35].…”

Section: Machining Of Rsa Materialsmentioning

confidence: 99%

Optimization of Surface Roughness of Aluminium RSA 443 in Diamond Tool Turning

Mbangu Tambwe,

Pons

2024

JMMP

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Context—Rapidly solidified aluminium alloy (RSA 443) is increasingly used in the manufacturing of optical mold inserts because of its fine nanostructure, relatively low cost, excellent thermal properties, and high hardness. However, RSA 443 is challenging for single-point diamond machining because the high silicon content mitigates against good surface finishes. Objectives—The objectives were to investigate multiple different ways to optimize the process parameters for optimal surface roughness on diamond-turned aluminium alloy RSA 443. The response surface equation was used as input to three different artificial intelligence tools, namely genetic algorithm (GA), particle swarm optimization (PSO), and differential evolution (DE), which were then compared. Results—The surface roughness machinability of RSA443 in single-point diamond turning was primarily determined by cutting speed, and secondly, cutting feed rate, with cutting depth being less important. The optimal conditions for the best surface finish Ra = 14.02 nm were found to be at the maximum rotational speed of 3000 rpm, cutting feed rate of 4.84 mm/min, and depth of cut of 14.52 µm with optimizing error of 3.2%. Regarding optimization techniques, the genetic algorithm performed best, then differential evolution, and finally particle swarm optimization. Originality—The study determines optimal diamond machining parameters for RSA 443, and identifies the superiority of GA above PSO and DE as optimization methods. The principles have the potential to be applied to other materials (e.g., in the RSA family) and machining processes (e.g., turning, milling).

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“…It concluded that the multi-step cutting process and the cutting depth of 1-2 µm can significantly reduce the burr height. Wu et al [12] processed V-grooves on the surface of electroplated copper and took Poisson burr height as the evaluation index of the processing quality to obtain the optimal cutting parameters of V-grooves. These scholars study the burrs in cutting V-grooves, which provides an idea for machining the highprecision original mold with the triangular pyramid texture.…”

Section: Introductionmentioning

confidence: 99%

Micro-burrs in machining original molds of an optical functional film with a triangular pyramidal texture

2021

J. Micromech. Microeng.

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During the cutting process of the original molds, the micro-burrs produced by the machining process will affect the optical properties of the optical functional textured film. According to the forming planing method for the triangular pyramid texture, the formation characteristics of burrs are analyzed from the cut-in edge and the cut-out edge. And the influence of burrs on the triangular pyramid edge is analyzed in combination with the changes of cutting section, to obtain the prediction model of edge burr distribution. The cutting simulation of triangular pyramid texture shows that the main flow direction of the chips will be inclined along the side where the cutting edge is separated from the workpiece first, resulting in a larger exit burr size on this side. In the cut-out stage, as the contact length between the cutting edge of the tool and the workpiece decreases gradually, the maximum cutting stress gradually transfers to the tool tip so that the positive burrs form at the bottom of the cut-out edges of the triangular pyramid. The forming processing experiment for the triangular pyramid texture shows that there are both positive and negative exit burrs on the cut-out edges. Compared with the forming processing method, the V-shaped section of the cutting layer is changed to the trapezoidal section of the free chips when the original molds with triangular pyramid texture are cut by the single-edge cutting method. As the chips flow more smoothly, the size of burrs can be reduced. Besides, the ratio of the effective optical functional area K s can increase 10.1%.

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Effect of cutting parameters on surface quality during diamond turning of micro-prism array

Cited by 12 publications

References 20 publications

Machinability of Stone—Plastic Materials During Diamond Planing

Machinability of Stone—Plastic Materials During Diamond Planing

Optimization of Surface Roughness of Aluminium RSA 443 in Diamond Tool Turning

Micro-burrs in machining original molds of an optical functional film with a triangular pyramidal texture

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