Experimental investigation on the ductile machinability of fused silica during in-situ laser assisted diamond cutting

Additive manufacturing technologies are beginning to shift toward hybridization with subtractive processes and it is vital to identify techniques that can enhance the machinability of the difficult-to-cut additively manufactured metals and offer easy integration. The mechanochemical effect, which can be induced by surfactant, is a feasible solution for hybrid integration due to the beneficial enhancements to the cutting performance, online integrability, and negligible impact on the AM process as compared to cutting fluids, cryogenic cutting, etc. To realize the successful integration of the mechanochemical effect and hybrid additive/subtractive manufacturing, micro-cutting of AMed high-strength maraging steel was performed to study the relationship between microstructural features, mechanical properties, cutting performance and effectiveness of the mechanochemical effect. The results show that the mechanochemical effect was successfully induced in the as-built and solution-treated steels by inhibiting dislocation movement to induce the embrittlement of chip surface and strain localization within the chip, thereby leading to substantial reductions in cutting forces of up to 35.24 % and 53.09 %, respectively, with significant improvement in the machined surface quality. However, the presence of 7.7 nm nanoparticles in the age-treated steels renders the mechanochemical effect ineffective in improving machinability. The nanoparticles sharply increased the strength, hardness, and brittleness of the AMed maraging steel where the brittleness replaced the role of surfactant that suppressed plasticity in the chip free surface. The notion was affirmed by the similarities between the cutting chips of the brittle aged steel without surfactant and the as-built steel with surfactant. This study systematically revealed the underlying mechanism of inducing the mechanochemical effect during the micro-cutting of AMed high-strength materials with different microstructures and mechanical properties. More importantly, it is evident that the mechanochemical effect is a highly feasible solution for enhanced hybrid manufacturing, especially for robot-based fabrication works that involve high degrees of freedom and large working ranges but are limited by low mechanical stiffness. 

Efficient post-processing of additive manufactured maraging steel enhanced by the mechanochemical effect

Ultra-precision machining of single-crystal silicon can be realized by applying single-point diamond turning with micro-laser-assisted machining technology, through which the ductility of silicon can be enhanced. However, it is difficult to explain the role of temperature accurately in such technology in a traditional manner. In this study, numerical simulation technology was utilized to obtain the temperature distribution conquering the limitations of the traditional measurement method. Besides, a diamond grooving simulation model considering the temperature effect was developed using the smoothed particle hydrodynamics (SPH) algorithm. The shortcoming of the accuracy of calculation brought by applying the finite element method can be overcome effectively. By analyzing the evolutions of cutting force, the ductile-to-brittle transition behavior was distinguished. The comparison of the quantitative values of critical depths of cut between the simulations and grooving experiments corroborated the high accuracy of the as-established SPH model. In addition, the significance of temperature on ductile-to-brittle transition is successfully divulged. The simulation results demonstrate that the critical depth of cut of ductile-to-brittle transition increases in pace with an increase in temperature due to the thermal softening effect, indicating the enhancement of ductile response of the material. This study provides a novel method for the investigation of ductile-to-brittle transition mechanism and the optimization of processing parameters of single-crystal silicon.

Effect of temperature on ductile-to-brittle transition in diamond cutting of silicon

Sustainability of Methods for Augmented Ultra-Precision Machining

Germanium lenses are widely used in various scientific and technological applications mainly infrared optical components. The performance of these lenses depends upon the surface finish, which is challenging to achieve during ductile-regime machining. It is crucial to provide the optimum parameters to ensure the high-quality surface, without surface and subsurface damage. In the present work, an attempt has been made to analyse the effect of input machining parameters on surface finish and subsurface damage distribution, induced during the diamond turning. Taguchi’s optimization has been performed to optimize the parameters affecting the performance and surface quality of fabricated components. Abbott–Firestone (A–F) curve is utilized to study the distribution of peaks and valleys on the machined surface. Additionally, chip morphology and machining forces are analysed to study the material removal behaviour at varying parameters. Further, indentations are performed on the best and worst combinations to examine the effect of parameters selection on surface cracks propagation. It is found that surface with a greater number of valleys leads to chipping during indentation. In this study, a surface roughness of 2.3 nm is achieved with minimum subsurface deformation.

Effect of machining parameters on surface finish and subsurface damage for diamond-turned germanium

A wide range of materials including metals and alloys, ceramics, glasses, semiconductors and composites are manufactured to meet service requirements to a given geometry, accuracy, finish and surface integrity. Metals and alloys in general are easier to machine because of their high fracture toughness, low hardness, non-directional bonding, low porosity, large strain to fracture and high impact energy. Non-metals, on the other hand, such as ceramics, semiconductors and optical crystals are characterized by covalent or ionic bonding, limited slip systems for plastic deformation, high hardness and low fracture toughness. It is due to these major differences that ceramics, semiconductors and optical crystals are considered more challenging to machine.

Micro-laser assisted machining: the future of manufacturing silicon optics

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Micro-laser assisted machining: the future of manufacturing silicon optics