Mechanism of burr accumulation and fracture pit formation in ultraprecision microgroove fly cutting of crystalline nickel phosphorus

Abstract

In precision glass molding (PGM) of glass materials with a high melting point, heat treatment of nickel phosphorus (Ni–P) should be made in advance to eliminate mold deformation during the high temperature molding. During the process, crystallization occurs on the plating and crystalline Ni–P with a particular micro-machinability is generated. Burrs of large sizes with a fibrous structure are observed on the microgroove ridge during the study of the fly cutting microgrooving. The Poisson burr accumulation in each material removal period is considered as the reason for the burr formation and a model of the burr accumulation in fly cutting is established based on the concept of maximum effective cutting thickness. According to the model, a high feed rate leads to the restriction of burr formation while fracture pits tend to be generated on the microgroove ridge. The fracture pits caused by the brittle removal of the material could be eliminated through the feed rate adjustment of fly cutting. The optimal processing parameter is proposed in consideration of the burr formation restriction and the elimination of fracture pits. The efficiency of microgroove mold machining is significantly improved. A high-quality microgroove mold is fabricated and the serviceability of the mold is tested through a PGM experiment.

Highly Sensitive P(VDF-TrFE)/BTO Nanofiber-Based Pressure Sensor with Dense Stress Concentration Microstructures

“…The fabrication process of the HD-μPA-based pressure sensor is shown in Figure a. HD-μPA was formed on a Cu block by an ultraprecision microgrooves fly cutting process Figure b presents the scanning electron microscopy (SEM) image of the Cu mold.…”

A review of the techniques for the mold manufacturing of micro/nanostructures for precision glass molding

“…Ultra-precision fly cutting (UPFC) is an intermittent cutting process in which a diamond tool is mounted with a spindle to intermittently cut a workpiece. Compared with planing technology, UPFC can be used to fabricate micro/nanostructures with a higher cutting speed, which produces a surface with higher quality [142,143]. According to the configuration, UPFC can generally be divided into radial fly cutting (RFC) and end fly cutting (EFC).…”