Thermal effects in single point diamond turning: Analysis, modeling and experimental study

Kumar, Jayant; Negi, Vipender Singh; Chattopadhyay, Kashidas; Sarepaka, RamaGopal V.; Sinha, R. K.

doi:10.1016/j.measurement.2017.01.046

Cited by 22 publications

(12 citation statements)

References 18 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The problem is more prominent for PC machining due to its low thermal diffusivity, and it significantly deteriorates the quality of PC optics. The net heat passed to the workpiece surface can be given in the following equations: 17 …”

Section: Resultsmentioning

confidence: 99%

See 1 more Smart Citation

Experimental investigations on ultra-precision machining of polycarbonate and related issues

Mishra

Sharma

Mahajan

et al. 2020

Journal of Micromanufacturing

Self Cite

View full text Add to dashboard Cite

Optical plastic lenses are progressively substituting glass optics due to their lightweight and low costs. Polycarbonate (PC) is considered as one of the leading optical materials due to its good mechanical and optical properties. Ultra-precision machining is the most suited process to develop PC optical components. Nevertheless, ultra-precision machining is considered as one of the deterministic processes to ensure the surface quality required for optical components. However, it is important to understand the behavior of the material during each stage of manufacturing. PC offers many challenges during its processing to achieve the nanometric finish and sub-micron form accuracies. In this article, the various issues of PC machining are discussed through experimental investigations. The effect of machining variables, that is, machining parameters, cutting temperature, and vacuum clamping on surface quality is studied. The results show the importance of the selection of optimum conditions for machining PC with good surface quality. The PC optical component is developed with surface finish ( Ra) 18.1 nm and profile accuracies ( Pv) of 0.116 µm. The study is helpful to understand the various issues involved in PC machining and hence to minimize their effects on surface quality.

show abstract

Section: Resultsmentioning

confidence: 99%

“…A wrong selection of machining parameters may change the temperature at the cutting zone. 16, 17 Unlike most thermoplastics, PC can undergo large plastic deformations under external forces, which makes the holding of PC more difficult. While dealing with sub-micron profile accuracies, this issue is more dominant.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigations on ultra-precision machining of polycarbonate and related issues

Mishra

Sharma

Mahajan

et al. 2020

Journal of Micromanufacturing

Self Cite

View full text Add to dashboard Cite

show abstract

“…IR temperature measurement employs a non-contact method for studying the temperature changes in various fields such as medical, aeronautical and manufacturing industries. This technique produces visual pictures of the temperature of silicon solar cells conveying information faster and easier [32]. Fig.…”

Section: Resultsmentioning

confidence: 99%

Development of sol-gel derived gahnite anti-reflection coating for augmenting the power conversion efficiency of polycrystalline silicon solar cells

Kaliyannan¹,

Palanisamy²,

Manivasakan

et al. 2019

Materials Science-Poland

View full text Add to dashboard Cite

The present research is focused on developing ZnAl2O4 (gahnite) spinel as an antireflection coating material for enhanced energy conversion of polycrystalline silicon solar cells (PSSC). ZnAl2O4 has been synthesized using dual precursors, namely aluminum nitrate nonahydrate and zinc nitrate hexahydrate in ethanol media. Diethanolamine has been used as a sol stabilizer in sol-gel process for ZnAl2O4 nanosheet fabrication. ZnAl2O4 nanosheet was deposited layer-by-layer (LBL) on PSSC by spin coating method. The effect of ZnAl2O4 coating on the physical, electrical, optical properties and temperature distribution in PSSC was investigated. The synthesized antireflection coating (ARC) material bears gahnite (ZnAl2O4) spinel crystal structure composed of two dimensional (2D) nanosheets. An increase in layer thickness proves the LBL deposition of ARC on the PSSC substrate. The ZnAl2O4 2D nanosheet comprising ARC on the PSSC was tested and it exhibited a maximum of 93 % transmittance, short-circuit photocurrent of 42.364 mA/cm2 and maximum power conversion efficiency (PCE) 23.42 % at a low cell temperature (50.2 °C) for three-layer ARC, while the reference cell exhibited 33.518 mA/cm2, 15.74 % and 59.1 °C, respectively. Based on the results, ZnAl2O4 2D nanosheets have been proven as an appropriate ARC material for increasing the PCE of PSSC.

show abstract

“…The precision tool for SPDT has to maintain an accurate cutting tool edge (tool nose radius) to machine in sub-micron/micron regions repeatedly, with minimal cutting forces under thermally unstable machining conditions and still has to deliver a workpiece with sub-micron-level waviness and nanometric roughness. 7–9…”

Section: Introductionmentioning

confidence: 99%

Study, analysis, and characterization of ultra-precision diamond tools for single-point diamond turning

Sarepaka¹,

Balan²,

Doodala³

et al. 2020

Journal of Micromanufacturing

Self Cite

View full text Add to dashboard Cite

In multiple applications of advanced instrumentation, single-point diamond turning (SPDT) is a popular and effective process to generate novel surfaces with nanometric surface roughness and sub-micron surface irregularities, albeit at a high cost. In SPDT, precision diamond tooling contributes significantly to the process cost escalation. Hence, for SPDT, it is vital to have an optimal precision diamond tool deployment. In this article, details of comprehensive precision diamond tool selection and tool characterization are discussed. Three makes of selected ultra-precision diamond (UPD) tools and standard diamond tools (of a global make), designated as CFT, are considered for this study. In this tool bench-marking exercise, the fabrication of Cu–Be alloy predesigned precision components (PDPCs) of a critical geometry is selected. UPD and CFT tools are deployed to fabricate (under similar machining-metrology conditions) the PDPCs. These diamond tools are evaluated in terms of the quality parameters (variation in radius of curvature, form error, and surface roughness) of the workpieces. Further, to explore the progressive wear of these tools, multiple machining cycles are conducted on these workpieces, and their quality parameters are analyzed. Thus, the precision diamond tools of three makes are benchmarked against the CFT tool. Based on the final outcome of this analysis, suitable recommendations are provided to precision diamond tool manufacturers to improve their product in terms of performance and optimized costs to meet the ever-growing tooling demands of the SPDT community.

show abstract

Thermal effects in single point diamond turning: Analysis, modeling and experimental study

Cited by 22 publications

References 18 publications

Experimental investigations on ultra-precision machining of polycarbonate and related issues

Experimental investigations on ultra-precision machining of polycarbonate and related issues

Development of sol-gel derived gahnite anti-reflection coating for augmenting the power conversion efficiency of polycrystalline silicon solar cells

Study, analysis, and characterization of ultra-precision diamond tools for single-point diamond turning

Contact Info

Product

Resources

About