Ultraprecision Metal Cutting — The Past, the Present and the Future

Ikawa, Naoya; Donaldson, R. R.; Komanduri, R.; König, Wilfried; Aachen, T.H.; McKeown, P.A.; Moriwaki, Toshimichi; Stowers, I. F.

doi:10.1016/s0007-8506(07)61134-2

Cited by 298 publications

(89 citation statements)

References 44 publications

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“…Moreover, the tool wear is closely related to the local cutting temperature [13,25,26]. Figures 12 (a)-(c) show the temperature distributions of tool tips under different depths of cut.…”

Section: Observation Of Tool Wearmentioning

confidence: 99%

Investigation of a scale-up manufacturing approach for nanostructures by using a nanoscale multi-tip diamond tool

Tong

Luo

Sun

et al. 2015

Int J Adv Manuf Technol

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Increasing interest in commercializing functional nanostructured devices heightens the need for cost effective manufacturing approaches for nanostructures. This paper presents an investigation of a scale-up manufacturing approach for nanostructures through diamond turning using a nanoscale multi-tip diamond tool (four tip tool with tip width of 150 nm) fabricated by focused ion beam (FIB). The manufacturing capacity of this new technique is evaluated through a series of cutting trials on copper substrates under different cutting conditions (depth of cut 100-500 nm, spindle speed 12-120 rpm). The machined surface roughness and nanostructure patterns are measured by using a white light interferometer and a scanning electron microscope, respectively. Results show that the form accuracy and integrity of the machined nanostructures were degraded with the increase of the depth of cut and the cutting speed. The burr and the structure damage are two major machining defects. High precision nano-grooves (form error of bottom width < 6.7 %) was achieved when a small depth of cut of 100 nm was used (spindle speed = 12 rpm). Initial tool wear was found at both the clearance cutting edge and the side edges of tool tips after a cutting distance of 2.5 km. Moreover, the nanometric cutting process was emulated by molecular dynamics (MD) simulations. The research findings obtained from MD simulation reveal the underlying mechanism for machining defects and the initialization of tool wear observed in experiments.

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“…Moreover, the tool wear is closely related to the local cutting temperature [13,25,26]. Figures 12 (a)-(c) show the temperature distributions of tool tips under different depths of cut.…”

Section: Observation Of Tool Wearmentioning

confidence: 99%

Investigation of a scale-up manufacturing approach for nanostructures by using a nanoscale multi-tip diamond tool

Tong

Luo

Sun

et al. 2015

Int J Adv Manuf Technol

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“…Moreover, single point diamond turning, which is flexible to make precise and complex micro/nano features on a lens surface, is not suitable for the most needed optical material, the Sibased optical glass. This is because silicate optical glass can easily produce severe cleavages and microchipping on a diamond tool surface and therefore bring about tool wear [34][35][36].…”

Section: Introductionmentioning

confidence: 99%

Precision glass molding: Toward an optimal fabrication of optical lenses

Zhang

Liu

2017

Front. Mech. Eng.

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It is costly and time consuming to use machining processes, such as grinding, polishing and lapping, to produce optical glass lenses with complex features. Precision glass molding (PGM) has thus been developed to realize an efficient manufacture of such optical components in a single step. However, PGM faces various technical challenges. For example, a PGM process must be carried out within the super-cooled region of optical glass above its glass transition temperature, in which the material has an unstable non-equilibrium structure. Within a narrow window of allowable temperature variation, the glass viscosity can change from 10 5 to 10 12 Pa$s due to the kinetic fragility of the super-cooled liquid. This makes a PGM process sensitive to its molding temperature. In addition, because of the structural relaxation in this temperature window, the atomic structure that governs the material properties is strongly dependent on time and thermal history. Such complexity often leads to residual stresses and shape distortion in a lens molded, causing unexpected changes in density and refractive index. This review will discuss some of the central issues in PGM processes and provide a method based on a manufacturing chain consideration from mold material selection, property and deformation characterization of optical glass to process optimization. The realization of such optimization is a necessary step for the Industry 4.0 of PGM.

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“…The technologies that have been utilized in micromachining are existing technologies adapted to the miniaturization of structures, devices and systems [1]. There are number of issues in micro-scale machining that are fundamentally different from macro-scale machining [2]. They include differences in the underlying mechanisms resulting in changes in the chip formation process, machining forces, specific energy and surface finish.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Tool Wear in Microturning of Ofhc Copper

P¹,

Gowri²,

Krishnamurthy³

2009

Int. Jour. Des. Manf. Tech.

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This paper presents experimental results of microturning of oxygen free high conductivity (OFHC) copper rods using cermet inserts of 0.1mm nose radius as cutting tool. Machining was done in DT-110 Integrated multiprocess micromachine tool. Full factorial experiments were conducted with various combinations of cutting speed, feed and depth of cut. Tool wear for different conditions were measured offline and also acoustic emission signals (AE rms) were recorded. Variations of tool wear with time and correlation between AE rms and tool wear were studied. Good correlation was observed between AE rms and tool wear. Also scanning electron microscope images of worn out inserts were analyzed to ascertain the wear mechanisms. It was found that mostly steady machining can be obtained with medium speed and feed.

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Ultraprecision Metal Cutting — The Past, the Present and the Future

Cited by 298 publications

References 44 publications

Investigation of a scale-up manufacturing approach for nanostructures by using a nanoscale multi-tip diamond tool

Investigation of a scale-up manufacturing approach for nanostructures by using a nanoscale multi-tip diamond tool

Precision glass molding: Toward an optimal fabrication of optical lenses

Experimental Study on Tool Wear in Microturning of Ofhc Copper

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