Investigation of Surface Integrity Induced by Ultra-Precision Grinding and Scratching of Glassy Carbon

Glassy carbon provides material characteristics that make it a promising candidate for use as a mould material in precision glass moulding. However, to effectively utilize glassy carbon, a thorough investigation into the machining of high-precision optical surfaces is necessary, which has not been t...

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Bibliographic Details
Published in:Micromachines (Basel) 2023-12, Vol.14 (12), p.2240
Main Authors: Jahnel, Kirk, Michels, Robert, Wilhelm, Dennis Patrick, Grunwald, Tim, Bergs, Thomas
Format: Article
Language:English
Subjects:
brittle material
Carbon
Cracks
Cutting parameters
Cutting speed
Diamond machining
Diamonds
Ductile fracture
ductile grinding
Electrons
Feed rate
Glassy carbon
Graphene
Graphite
Grinding
Integrity
Investigations
Kinematics
Machining
Manufacturing
Microstructure
Molding (process)
nano-scratch
Plastic deformation
Scratching
surface integrity
Surface roughness
Temperature
ultra-precision grinding
Yield stress
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Summary:Glassy carbon provides material characteristics that make it a promising candidate for use as a mould material in precision glass moulding. However, to effectively utilize glassy carbon, a thorough investigation into the machining of high-precision optical surfaces is necessary, which has not been thoroughly investigated. This research analyses the process of material removal and its resulting surface integrity through the use of nano-scratching and ultra-precision grinding. The nano-scratching process begins with ductile plastic deformation, then progresses with funnel-shaped breakouts in the contact zone, and finally concludes with brittle conchoidal breakouts when the cutting depth is increased. The influence of process factors and tool-related parameters resulting from grinding has discernible impacts on the ultimate surface roughness and topography. Enhancing the cutting speed during cross-axis kinematic grinding results in improved surface roughness. Increasing the size of diamond grains and feed rates leads to an increase in surface roughness. An achievable surface roughness of Ra < 5 nm together with ductile-regime grinding behaviour meet optical standards, which makes ultra-precision grinding a suitable process for optical surface generation.
ISSN:2072-666X
2072-666X
DOI:10.3390/mi14122240