Effect of cutting parameters on surface quality in ductile cutting of KDP crystal using self-developed micro PCD ball end mill
Effect of cutting parameters on surface quality in ductile cutting of KDP crystal using self-developed micro PCD ball end mill
复制标题
自主研发微型PCD球头立铣刀韧性切削KDP晶体时切削参数对表面质量的影响
DOI：
10.1007/s00170-014-6623-8
复制
发表时间：
2015-04-01
影响因子：
3.4
通讯作者：
Wang, Xuebin
中科院分区：
文献类型：
--
作者：
Chen, Ni;Chen, Mingjun;Wang, Xuebin
微铣削被广泛认为是修复 KH2PO4(KDP) 表面微缺陷的最有前途的方法。为了获得优良的工件表面质量，必须实现KDP晶体的延性切削。与塑料材料（如金属）相比，由于KDP晶体的软脆性，其韧性切削对刀具的几何参数和切削参数更加敏感。本文通过仿真得到了切削力峰谷值（P-V）对切削参数的变化规律，与自行设计的微型聚晶金刚石（PCD）球头立铣刀的单因素实验结果吻合较好。同时，通过单因素实验还获得了KDP晶体的韧性切削参数。然后，进行正交实验，结果表明轴向切削深度和进给速度分别对粗糙度值Ra有最大和最小的影响。此外，还获得了最佳切削参数，即主轴转速（7 × 104r/min）、轴向切削深度（0.5μm）和进给速度（30mm/min）。最后，将上述得到的最佳切削参数用于修复实验，证明是良好的切削参数，获得了良好的修复轮廓表面质量；同时，还验证了自主研发的微型PCD球头立铣刀的修复性能。
Micro-milling is widely accepted as the most promising approach to repair the micro-defects on the KH2PO4(KDP) surface. In order to get excellent surface quality of workpiece, the ductile cutting of KDP crystal should be achieved. Compared to plastic materials (e.g., metals), the ductile cutting of KDP crystal is more sensitive to the geometrical parameters of tools and cutting parameters, as a result of the soft brittle properties of KDP crystal. In this work, the variable regularity of peak to valley (P-V) value of cutting force on cutting parameters was obtained through simulations, which was matched well with the results obtained from the single-factor experiments using the self-designed micro polycrystalline diamond (PCD) ball end mill. Meanwhile, the ductile cutting parameters of KDP crystal were also obtained through the single-factor experiments. Then, the orthogonal experiments were explored which reveal that the axial depth of cut and the feed speed had maximal and minimal influences on the roughness valueRa, respectively. Moreover, the optimal cutting parameters which are the spindle speed (7 × 104r/min), axial depth of cut (0.5 μm), and feed speed (30 mm/min) were also gained. At last, the optimal cutting parameters obtained above which were used in the repairing experiments were proved to be good cutting parameters because the good surface quality of repairing outlines was achieved; meanwhile, the repairing performance of self-developed micro PCD ball end mill was also verified.