Investigation on the ultra-precision diamond turning of ZnSe aspheric surfaces using straight-nosed cutting tools

Sun，Linhe1,3; Duan，Wenhong2; Wu，Hanqiang1; Chen，Minghan1; Zeng，Jiang1; Wu，Yongbo1; Chen，Yuhan1

2023-10-27

10.1016/j.jmapro.2023.09.011

Journal of Manufacturing Processes   Impact Factor & Quartile

1526-6125

2212-4616

Theoretical and experimental investigations on the machining performance and mechanisms in single-point diamond turning (SPDT) of ZnSe aspheric surfaces using straight-nosed cutting tools have been carried out. Analyses of the chip formation process have shown that using straight-nosed cutting tools can significantly reduce the cut thickness by about 60 % compared with using round-nosed cutting tools for facilitating the ductile-mode material removal and reducing surface damages. The analyses have also shown that the height of residual feed marks can be reduced by using the straight-nosed cutting tools by about 80 %, which can further improve the machined surface integrity. Experiments on the machining performance of using straight-nosed and round-nosed cutting tools were conducted to verify the analytical deductions. It has been shown that nano-scale surface finish with surface roughness Ra ∼ 1.5 nm can be achieved by using straight-nosed cutting tools, which is significantly improved comparing with that by the round-nosed cutting tools (Ra ∼ 7.8 nm) and is consistent with the analytical results. Needle-like chip with periodical layered structure was collected from the SPDT processes using straight-nosed cutting tools, indicating a relatively continuous chip formation process under the ductile-mode material removal. Raman spectroscopy has shown increased metallization of ZnSe occurred during the machining with straight-nosed cutting tools, which is considered to reduce the brittle fractures along with the chip formation process. It has been further found that the straight-nosed cutting tool can reduce work adhesion and micro-edge chipping of cutting tools for extending the cutting tool life.

Aspheric surfaces Cutting tool wear Single-point diamond turning Straight-nosed cutting tools Surface integrity Ultra-precision machining

SCI

English

First ; Corresponding

National Natural Science Foundation of China[51975269];

Engineering

Engineering, Manufacturing

WOS:001076081000001

ELSEVIER SCI LTD

2-s2.0-85170270909

Scopus

1.Department of Mechanical and Energy Engineering,Southern University of Science and Technology,Guangdong,518055,China
2.Shenzhen Yuhe Diamond Tool Co.,Ltd.,Shenzhen,518055,China
3.Department of Industrial and Systems Engineering,The Hong Kong Polytechnic University,Hong Kong,Hung Hom, 6 Kowloon,Hong Kong

Sun，Linhe,Duan，Wenhong,Wu，Hanqiang,et al. Investigation on the ultra-precision diamond turning of ZnSe aspheric surfaces using straight-nosed cutting tools[J]. Journal of Manufacturing Processes,2023,104:108-122.

Sun，Linhe.,Duan，Wenhong.,Wu，Hanqiang.,Chen，Minghan.,Zeng，Jiang.,...&Chen，Yuhan.(2023).Investigation on the ultra-precision diamond turning of ZnSe aspheric surfaces using straight-nosed cutting tools.Journal of Manufacturing Processes,104,108-122.

Sun，Linhe,et al."Investigation on the ultra-precision diamond turning of ZnSe aspheric surfaces using straight-nosed cutting tools".Journal of Manufacturing Processes 104(2023):108-122.