Two-Dimensional Cutting of Polycrystalline Diamond and CBN Tools and Dies using a Novel Laser/Waterjet Hybrid Manufacturing Process

本项目的目标是检验以下两个假设：1）激光和水射流的联合作用将导致二维切割过程中垂直于切割路径的拉应力的发展和裂纹沿着切割路径的扩展（激光切割）或材料腐蚀（电火花加工）通过裂纹扩展进行材料分离，然后形成更小的切口;平行壁;在加工两种材料时，可以获得更高的切削速度和大量的能量节省，多晶金刚石和多晶立方氮化硼的尺寸分布与常规加工工艺相比。 该项目的方法是通过基本断裂力学模型和实验来验证假设，研究激光加热和水射流淬火的热效应和化学效应对超硬材料的控制断裂。研究活动的成功完成将导致一种新的脆性材料加工方法，沿着对这种新方法背后的基本原理的详细理解。 这种新的混合制造工艺将有可能分别为金属切削和拉丝行业提供高性能的工具和模具。 汽车、木工和其他使用合成金刚石工具的行业将从这项研究中受益匪浅。 教育和推广成果将包括对研究生进行先进制造研究方面的培训，将研究成果融入新的课程模块，让研究团队中代表性不足的群体的本科生参与，以及通过期刊出版物、会议和行业访问和研讨会传播研究成果。

The objective of this project is to test the following two hypotheses: 1) the combined action of laser and waterjet will result in development of tensile stresses perpendicular to cutting path and propagation of cracks along cutting path during the two-dimensional cutting and 2) if the material removal mechanism were changed from thermal melt and evaporation (laser cutting) or material erosion (electrical discharge machining) to material separation through crack propagation, then smaller kerf; parallel walls; higher cutting speed and substantial energy savings can be attained in the machining of two-dimensional profiles of polycrystalline diamonds and polycrystalline cubic boron nitride over conventional machining processes. The project's approach is to test the hypotheses relies on fundamental fracture mechanics modeling and experiments to investigate controlled fracture of superhard materials due to thermal and chemical effects of laser heating and waterjet quenching.Successful completion of the research activities will lead to a novel machining method for brittle materials along with a detailed understanding of the fundamental underpinnings behind this new process. This novel hybrid manufacturing process will have potential to offer high performance tools and dies for metal cutting and wire drawing industries respectively. Automotive, woodworking and other industries that use synthetic diamond tools would greatly benefit from this research. Education and outreach outcome will include training of graduate students in advanced manufacturing research, assimilation of the research outcomes into new course modules, the involvement of undergraduates from underrepresented groups in the research team and the dissemination of the research results through journal publications, conferences and industry visits and workshops.