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Study on the edge chipping and tool life in ultrasonic-vibration-assisted grinding of sapphire: A hole making process integration of tool design and tool path design

机译:蓝宝石超声波振动磨削边缘切削和工具寿命研究:工具设计与工具路径设计的孔制作整合

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Edge chipping and tool life are two of the most serious issues during machining process of brittle materials. Ultrasonic vibration cutting is considered relatively low cutting force and high machining efficiency for machining hard and brittle materials. To find an effective method considering the effect of grit size of diamond coated grinding head, tool geometry and tool path to reduce edge chipping and increase tool life using ultrasonic-vibration-assisted grinding in drilling and enlarging hole process of sapphire glass is studied in this paper. There are three aspect to study the strategy of controlling edge chipping in this paper: (a) The designed experiments reveal the effects on cutting force, edge chipping and tool life with different tool geometry design (taper angle and chip groove ) in hole drilling process. The result shows that edge chipping can be reduced effectively by optimizing the taper angle and chip groove of tool design. (b) The relationship between grit size and edge chipping is revealed by investigating the microscope view of cutting behavior and several experiments are designed and conducted. (c) The tool path affects on tool life in hole enlarging process is investigated. To increase tool life and obtain smaller edge chipping thickness, a tool path strategy is obtained in this research: 3D spiral tool path method. With 3D spiral tool path method in hole enlarging process, tool wear will be much more well-distributed compare to traditional concentric circles tool path, so better tool life will be obtained.
机译:边缘切削和刀具寿命是脆性材料加工过程中最严重的两个问题。超声波振动切割被认为是相对较低的切割力和用于加工硬质材料的高加工效率。为了找到一种有效的方法,考虑了金刚石涂层磨头的砂砾尺寸的效果,研究了刀具几何和工具路径,以减少边缘碎片,使用超声波辅助研磨在钻孔玻璃钻孔和扩大孔过程中使用超声波振动辅助磨削的工具寿命纸。有三个方面研究了本文的控制边缘切削策略:(a)设计实验揭示了在孔钻井过程中具有不同工具几何设计(锥角和芯片槽)的切削力,边缘切削和工具寿命的影响。结果表明,通过优化工具设计的锥角和芯片槽,可以有效地减小边缘碎裂。 (b)通过研究切割行为的显微镜视图,揭示了砂砾尺寸和边缘切削之间的关系,并设计了几个实验。 (c)研究了刀具路径影响孔寿命在孔扩大过程中。为了提高刀具寿命并获得更小的边缘切削厚度,在本研究中获得了工具路径策略:3D螺旋工具路径方法。通过在空穴扩大过程中的3D螺旋刀具路径方法,刀具磨损将与传统同心圆刀具路径相比,刀具均匀,因此将获得更好的刀具寿命。

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