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Research Progress

Scientists Develop Multi-axis Milling and Rotary Ultrasonic Machining in Quartz and Alumina Ceramic

Mar 13, 2017

Rotary ultrasonic milling is a complex machining mode of diamond milling tool with high frequency vibration along with axial ultrasonic vibration and feed milling motion, and it has excellent processing capacity for hard and brittle materials to provide efficient and effective solution.

Its material removal method is the superimposition of high-frequency vibration, slip, plow and abrasion effects by diamond abrasive grains. The milling parameters such as spindle speed, feed speed, depth of cut and ultrasonic amplitude significantly affect the final workpiece surface quality.

Dr. CHEN Xiaoxiao's group at Ningbo Institute of Materials Technology and Engineering of Chinese Academy of Sciences combined the high-speed multi-axis milling with ultrasonic function to develop a variety of manufacturing principles and technical advantages of the physical. They found the quantitative indicators of multi-axis ball end cutter and the area of workpiece with a significant change in tool inclination angles.

Control of the tool axis vector is a key problem in multi-axis machining. Process optimization is the bridge of engineering application. The inclination effect of surface quality directly affects the final formed surface. The effects of inclination angles and milling mode on the machined surface quality were systematically studied. By process optimization research, the ideal process conditions were refined.

For quartz glass, engineering ceramics and other hard and brittle materials, researchers carried out a series of experiments and Finite Element Method (FEM) simulation for rotary ultrasonic face milling of quartz glass.

Quartz glass is widely used in many fields due to its high temperature resistance, low expansion coefficient, thermal shock resistance, high chemical stability, etc. And elastic recovery and plastic deformation of quartz glass were confirmed by nano-indentation test in the load after the excitation. The effects of process parameters on surface roughness and surface morphology under multi-axial conditions were analyzed.

The results show that the reasonable control of ultrasonic and process parameters is beneficial to achieve high-quality surface processing under the premise of improving efficiency.

A new method of high precision laser preforming micro-texture combined with ultrasonic milling and the configuration of the functional structure of the processing system are proposed by process innovation.

For the alumina ceramic with 99% content, laser microstructure pretreatment with nanosecond laser by the methods of single-point multi-pulse process and ring-cutting process were carried out.

It was found that it is easy to realize high efficiency, smaller residual stress pore array micro-texture array processing by single-point multi-pulse processing, and processing quality-dependent spot quality could be optimized by ring-cutting process parameters to improve the pit quality, larger processing aperture and greater residual compressive stress could be produced.

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