金刚石线锯切割大直径SiC单晶

采用金刚石线切割大直径的SiC单晶,研究了金刚石线锯的切割机理和切割参数,给出切割SiC单晶的实验结果.研究了金刚石线的寿命及各切割参数对线径减少量、翘曲度、表面粗糙度的影响.用光学显微镜观察了磨损的金刚石线和切割表面.     

Analysis of Surface Integrity in Drilling Metal Matrix and Hybrid Metal Matrix Composites

Hybrid metal matrix composites consist of at least three constituents-a metal or an alloy matrix and two reinforcements in various forms, bonded together at the atomic level in the composite. Despite their higher specific properties of strength and stiffness, the non homogeneous and anisotropic nature combined with the abrasive reinforcements render their machining difficult. In this paper, the surface integrity of machining in drilling hybrid composites has been discussed. Drilling tests are carried out at different spindle speed, feed rates, and different drill tool materials to investigate the effect of the various cutting parameters on the surface quality and the extent of the deformation of drilled surface due to drilling. Materials used for the present investigation are Al356/10SiC (wt%) metal matrix and Al356/10SiC-3mica (wt%) hybrid composites. The composites are fabricated using stir casting route. The drilling tests are conducted on vertical computer numeric control (CNC) machining center using carbide, coated carbide and polycrystalline diamond (PCD) drills. The surface roughness decreases with increasing spindle speed and increases with increasing feed rate. The machined surface is analyzed by scanning electron microscopy (SEM). SEM images of the machined surfaces indicate the presence of grooves and pits. Microhardness depth profiles indicate that the subsurface damage is limited to the top of 100-250 μm.     

Substrate roughness,deposit thickness and the corrosion of electroless nickel coatings

The affect of substrate roughness and coating thickness on the corrosion resistance of electroless nickel coatings on mild steel in a 0.99M Na₂SO₄ + 0.01 M H₂SO₄ + 0.05M NaCl solution has been investigated using electrochemical techniques. The coating was electrochemically more active than pure nickel. The anodic polarization, corrosion potential, and corrosion current depend on the substrate roughness and coating thickness. The substrate roughness decreased for finishes in the order, as-ground, 240 grit, 600 grit, and 1 m diamond polish, but the corrosion current on relatively thin coatings decreased in the order 240 grit, as-ground, 600 grit, and 1 m diamond finish. The corrosion potential and the corrosion current of coatings more than about 10m thick were independent of the surface roughness and similar to those observed with pure nickel. The fraction porosity was estimated to be about 0.005 in a coating about 5 m thick on a 600 SiC grit substrate.     

Surface integrity and removal mechanism in grinding sapphire wafers with novel vitrified bond diamond plates

In order to improve machining efficiency of sapphire wafer machining using the conventional loose abrasive process, fixed-abrasive diamond plates are investigated in this study for sapphire wafer grinding. Four vitrified bond diamond plates of different grain sizes (40?µm, 20?µm, 7?µm, and 2.5?µm) are developed and evaluated for grinding performance including surface roughness, surface topography, surface and subsurface damage, and material removal rate (MRR) of sapphire wafers. The material removal mechanisms, wafer surface finish, and quality of the diamond plates are also compared and discussed. The experiment results demonstrate that the surface material is removed in brittle mode when sapphire wafers are ground by the diamond plates with a grain size of 40?µm and 20?µm, and in ductile mode when that are ground by the diamond plates of grain sizes of 7?µm and 2.5?µm. The highest MRR value of 145.7?µm/min is acquired with the diamond plate with an abrasive size of 40?µm and the lowest surface roughness values of 3.5?nm in Ra is achieved with the 2.5?µm size.     

3D Characterization of super-smooth surfaces of diamond turned OFHC copper mirrors

In this study, super-smooth surfaces of oxygen-free high-conductivity copper mirrors obtained by single point diamond turning were characterized with an atomic force microscope from the three-dimensional (3D) point of view. The machining conditions were also studied. A program developed in this study for a unified approach to 3D surface finish assessment proposed by the Commission of European Community was used to obtain the 3D parameters. The feed rate was changed from 0.2 to 2.0 μm per revolution and 0.3-3.0 μm per revolution, respectively, in two experiments. By 3D roughness characterization of these surfaces, the optimal feed rate was found to be 1.4 μm per revolution when cutting depth was 1 μm or 0.9-1.2 μm per revolution at a cutting depth of 2 μm, where an S_q of 2.6 and 2.3 nm could be obtained, respectively. The suggested 3D roughness characterization parameters may include S_q, S_sk, S_ku, S_tr, S_al, S_Δq, and one functional parameter, such as S_bi.     

Effect of aging on the abrasive wear properties of AlMgSi1 alloy

In this paper, the wear performance of the aged AlMgSi1 alloy was investigated. Great improvements in mechanical properties of Al alloys can be achieved by suitable solution treatment and aging operations. A pin-on-disk wear machine was designed and developed for abrasive wear tests. The wear resistance was evaluated using a pin-on-disk wear testing method with a SiC abrasive paper counterface. The variation of wear volume is presented as a function of applied normal load, abrasive grit size and sliding distance for running speed. Mass losses were measured within a load range of 6.45–11 N, a sliding velocity range of 0.078–0.338 m/s and abrasive grit size of 5–30 μm. The effects of different sliding speeds and loads on wear resistance and surface roughness were also examined. It was measured amounts of mass loss and examined worn surfaces. Metal microscope was used to study the microstructures of the wear scars. Natural aged specimen observed maximum wear resistance.     

3D characterization of super-smooth surfaces of diamond turned OFHC copper mirrors

In this study, super-smooth surfaces of oxygen-free high-conductivity copper mirrors obtained by single point diamond turning were characterized with an atomic force microscope from the three-dimensional (3D) point of view. The machining conditions were also studied. A program developed in this study for a unified approach to 3D surface finish assessment proposed by the Commission of European Community was used to obtain the 3D parameters. In two experiments, the feed rate was changed from 0.2 to 2.0 μm per revolution and 0.3 to 3.0 μm per revolution, respectively. By 3D roughness characterization of these surfaces, the optimal feed rate was found to be 1.4 μm per revolution when the cutting depth was 1 μm or 0.9-1.2 μm per revolution at a cutting depth of 2 μm, where an S_q of 2.6 and 2.3 nm could be obtained, respectively. The suggested 3D roughness characterization parameters may include S_q, S_sk, S_ku, S_tr, S_al, S_Δq, and one functional parameter, such as S_bi.     

Abrasive Flow Polishing of Micro Bores

Micro bore finishing for metal and ceramic materials has been a challenge in the manufacturing industry. Unfortunately, little is understood about how to polish a micro bore and how to assess its inner wall quality because it is difficult to access the micro bore for either polishing or measurement. This article reports on a feasibility study of the abrasive flow polishing of micro bores of 260 ~ 500-µm diameters and 25 ~ 50 length/diameter ratios for both metal and ceramic materials. An abrasive flow polishing machine was designed and built with turbulent flow characteristics. Polishing of steel S45C bores of 400- and 500-µm diameters, stainless steel 304 bores of 500-µm diameter, and zirconia bores of 260-µm diameter was conducted. Surface roughness and topography of the polished inner walls of micro bores were characterized using profilometry and optical interferometry from the three-dimensional point of view. Significant reduction in surface roughness of the micro bore inner walls has been made in the polishing processes. The results indicate that it is feasible to apply the abrasive flow polishing technology for metal and ceramic micro bores of diameters of 260 µm or larger and the length/diameter ratios of 25 or higher. It is found that surface roughness of the polished micro bore inner walls decreases with an increase of the abrasive flow passes.     

Effect of negatively charged species on the growth behavior of silicon films in hot wire chemical vapor deposition

The deposition behavior of silicon in hot wire chemical vapor deposition was investigated, focusing on the generation of negatively charged species in the gas phase using a gas mixture of 20% SiH₄ and 80% H₂ at a 450 °C substrate temperature under a working pressure of 66.7 Pa. A negative current of 6–21 µA/cm² was measured on the substrate at all processing conditions, and its absolute value increased with increasing wire temperature in the range of 1400 °C–1900 °C. The surface roughness of the films deposited on the silicon wafers increased with increasing wire temperature in the range of 1510 °C–1800 °C. The film growth rate on the positively biased substrates (+ 100 V, + 200 V) was higher than that on the neutral (0 V) and negatively biased substrates (− 100 V, − 200 V, − 300 V). These results indicate that the negatively charged species are generated in the gas phase and contribute to deposition. The surface roughness evolved during deposition was attributed to the electrostatic interaction between these negatively charged species and the negatively charged growing surface.     

PARTICLE-SIZE DISTRIBUTION INFLUENCE IN HIGH-SPEED EROSION OF ALUMINIUM

The paper discusses the influence of the abrasive particle-size distribution on typical high speed abrasive-waterjet erosion parameters. The size distributions of the used abrasive particles are modelled by a Rosin-Rammler-Sperling (RRSB) grain-size distribution containing the distribution parameters D and n. Both parameters are independently varied to characterise different particle-size distributions. Aluminium specimens are eroded by abrasive-waterjets at velocities of 320 m/s, and the erosion depth, depth distribution, and the surface roughness are measured. The depth distribution and the surface roughness are very sensitive to the particle-size distribution parameters, whereas the average erosion depth is not influenced significantly. These results offer the possibility to select an “optimum” grain-size distribution for maximum surface quality at fixed kinematics conditions.     

Study of the moderate-temperature growth process of optical quality synthetic diamond films on quartz substrates

Growth of undoped and boron-doped diamond films on quartz substrates at moderate temperature of 500 °C by microwave plasma chemical vapor deposition method was studied in terms of growth rate, surface roughness and optical transmittance. Similar density of diamond seed particles on quartz surfaces seeded mechanically before the deposition process and diamond grains within diamond films grown on those substrates is observed. The growth rate is found similar to that reported for diamond deposited on silicon substrates in the same plasma deposition system, although with substantially higher activation energy. Furthermore, increased level of dopant concentration in the gas mixture resulted in a decrease of the growth rate, while a gradual reduction of the surface roughness occurred at high dopant levels. Overall, the highest measured regular optical transmittance of the undoped diamond film on quartz was 45% at 1100 nm (including quartz absorption), whereas that of boron-doped diamond peaked 5% at 700 nm (tail absorption of boron centers).     

Prediction and control of surface roughness for the milling of Al/SiC metal matrix composites based on neural networks

In recent years, there has been a significant increase in the utilization of Al/SiC particulate composite materials in engineering fields, and the demand for accurate machining of such composite materials has grown accordingly. In this paper, a feed-forward multi-layered artificial neural network (ANN) roughness prediction model, using the Levenberg-Marquardt backpropagation training algorithm, is proposed to investigate the mathematical relationship between cutting parameters and average surface roughness during milling Al/SiC particulate composite materials. Milling experiments were conducted on a computer numerical control (CNC) milling machine with polycrystalline diamond (PCD) tools to acquire data for training the ANN roughness prediction model. Four cutting parameters were considered in these experiments: cutting speed, depth of cut, feed rate, and volume fraction of SiC. These parameters were also used as inputs for the ANN roughness prediction model. The output of the model was the average surface roughness of the machined workpiece. A successfully trained ANN roughness prediction model could predict the corresponding average surface roughness based on given cutting parameters, with a 2.08% mean relative error. Moreover, a roughness control model that could accurately determine the corresponding cutting parameters for a specific desired roughness with a 2.91% mean relative error was developed based on the ANN roughness prediction model. Finally, a more reliable and readable analysis of the influence of each parameter on roughness or the interaction between different parameters was conducted with the help of the ANN prediction model.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00326-x     

Self Catalyzing Behavior of Kanthal Wire for Coating of Carbon Nanotubes

Carbon nanotubes (CNTs) were coated on kanthal wire without using any external transition metal catalyst. It was synthesized through thermal chemical vapour deposition technique at 800°C and in a flow of gas mixtures, that is, 100 sccm nitrogen, 25 sccm hydrogen and 20 sccm acetylene. Iron and chromium oxides from the surface of kanthal wire activate in hydrogen environment to form Fe-Cr particles. These Fe-Cr bimetallic catalyst particles then catalyze to grow CNTs on the surface of kanthal wire. It was characterized through scanning electron microscopy, energy dispersive X-ray analysis and atomic force microscopy.     

立方碳化硅CMP过程中机械作用分子动力学仿真

为了更好地理解立方碳化硅在化学机械抛光(CMP)过程中原子层面的材料去除机理,利用分子动力学(MD)方法建立了金刚石磨粒刻划碳化硅的原子模型,仿真研究了金刚石磨粒半径、刻划深度和刻划速度对碳化硅表面形貌、晶体结构、摩擦力和原子去除率的影响规律,并与无定型二氧化硅氧化膜的机械刻划作用的仿真结果进行了对比分析.结果发现:碳化硅在机械刻划过程中局部会出现非晶态变化;刻划深度增大会导致切削力和切削温度增大,原子去除率也随之增加;刻划速度的改变会影响温度和原子去除率,而对切削力几乎无影响;磨粒半径的增加会导致切削力和温度的增加,在压入深度相同的情况下对原子去除率影响不大;碳化硅表面生成的二氧化硅膜能大幅度降低切削力,但由于其结构的影响,机械刻划作用仅使氧化膜产生明显的致密化,而不产生磨屑.     

On theoretical substantiation of the choice of effective grain profile shape in modeling of diamond layer in dressing tools. Part 2. Electroforming

The paper describes, from the statistical standpoint, the mechanism of formation of spherical shape of the averaged cross section of scratches produced by flat faces of diamond grains in abrasive material of grinding wheels during their dressing with diamond rolls manufactured by electroforming. The distribution of parameters of orientation of diamond grain cutting faces has been determined and a brief comparative analysis of characteristics of dressing tools manufactured by electroforming and electroplating has been performed. A notion of the reduced effective diameter has been introduced into the model representation of a diamond cutting grain; a relationship between this diameter and the tool grain size has been found, which is needed for calculating individual and total cross-sections of cuts, dressing forces, and surface roughness of workpieces ground with pre-dressed abrasive wheels.     

Surface characterization of SiC whisker/2124 aluminium and Al2O3 composites machined by abrasive water jet

The machinability of two classes of high-temperature composites (SiC whisker/2124 aluminium and SiC whisker/Al₂O₃) with an abrasive waterjet (AWJ) was investigated. The as-machined surfaces of the composites were characterized by scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), and profilometry to determine the surface finish. Microhardness measurements were also performed on the as-machined metal matrix composites. AWJ appears to be a quite promising machining method due to its fast speed and economical operation. It gives relatively smooth surfaces coupled with minimum subsurface microstructural damage.     

单晶金刚石机械研磨结合化学辅助机械抛光组合加工工艺

单晶金刚石因具有最高的硬度和最低的摩擦系数常被用来制备超精密刀具,而表面粗糙度是影响刀具寿命的重要指标.提出采用机械研磨结合化学辅助机械抛光的组合工艺抛光单晶金刚石.实验优化并确定的加工工艺如下:先用5μm和2μm金刚石粉研磨单晶金刚石表面,然后采用化学机械的方法去除机械研磨带来的损伤.用该工艺抛光单晶金刚石,表面粗糙度Ra可达0.8 nm(测量区域70μm×53μm).表面拉曼光谱分析表明化学机械抛光的表面只有1 332 cm-1拉曼峰.     

Investigating the feasibility of using a grit blasting process to coat nitinol stents with hydroxyapatite

This study investigates the feasibility of utilising a grit blasting process to coat three nitinol substrates (a planer 2D surface, a circular wire and a cardiovascular stent geometry) with a hydroxyapatite coating. Surface characteristics of the coating on the three substrates were determined and additionally the durability of the coating post fatigue testing was analysed. The coating process resulted in a consistent covering of the substrate that resulted in an extremely hydrophilic stent surface. The surface roughness was dependant on grit blasting particle size. A general trend of smaller particle size resulted in a lower surface roughness, while particle size did not have an effect on the hydroxyapatite coating thickness. Fatigue integrity tests that simulated 16 months implantation demonstrated minimal damage to the coating. In conclusion we demonstrated the initial feasibility of using a grit blasting method to produce a consistent, hydrophilic, and durable HAp stent coating that has the capability of incorporating a drug eluting function.     

Molecular dynamics simulation model for the quantitative assessment of tool wear during single point diamond turning of cubic silicon carbide

Silicon carbide (SiC) is a material of great technological interest for engineering applications concerning hostile environments where silicon-based components cannot work (beyond 623 K). Single point diamond turning (SPDT) has remained a superior and viable method to harness process efficiency and freeform shapes on this harder material. However, it is extremely difficult to machine this ceramic consistently in the ductile regime due to sudden and rapid tool wear. It thus becomes non trivial to develop an accurate understanding of tool wear mechanism during SPDT of SiC in order to identify measures to suppress wear to minimize operational cost.In this paper, molecular dynamics (MD) simulation has been deployed with a realistic analytical bond order potential (ABOP) formalism based potential energy function to understand tool wear mechanism during single point diamond turning of SiC. The most significant result was obtained using the radial distribution function which suggests graphitization of diamond tool during the machining process. This phenomenon occurs due to the abrasive processes between these two ultra hard materials. The abrasive action results in locally high temperature which compounds with the massive cutting forces leading to sp³-sp² order-disorder transition of diamond tool. This represents the root cause of tool wear during SPDT operation of cubic SiC. Further testing led to the development of a novel method for quantitative assessment of the progression of diamond tool wear from MD simulations.     

The Impact of Tool Material and Cutting Parameters on Surface Roughness of a Nickel-Base Superalloy

The objective of the present work, is to assess the effect of tool material and cutting parameters on surface roughness of the supermet 718 Nickel-base superalloy, under dry cutting conditions and a constant nose radius (0.5 mm). The parameters investigated are cutting speed, feed rate, depth of cut and tool material. The tool materials used were the ceramic (Sandvik CC 680) and the CBN (Sandvik CB 50) inserts. These variables were investigated using a 2^k factorial design.

The present work demonstrates a favorable effect for ceramic inserts on surface roughness, when compared with CBN inserts. The work also, showed that the feed rate has the dominant effect among the parameters studied on the surface roughness, irrespective of the tool material used.