Thrust Force Directional Vibration-Assisted Cutting Based on a Removal Process of Ductile-Mode Grinding

―An Effect of Increased Ductile-Mode Surface for Cutting of Synthetic Silica Glass―

Abstract

Our research introduced a 40kHz thrust force directional vibration-assisted ductile-mode grinding of hard and brittle materials. And, the vibration-assisted grinding was adopted in order to avoid brittle fracture on the ground surface. But, the cause of this result could not be proved, because it was difficult to investigate removal process by many and various abrasive grains. Therefore, this study describes an evaluation of ductile-brittle transition with thrust force directional vibration-assisted cutting. Because the movement of cutting tool edge is similar to that of a grain on grinding wheel with the vibration. Then, cutting tool is oscillated by Fast Tool Servo actuator, and the frequency 1.00 kHz and amplitude 1.33 µm. In this cutting process, some intermittent cutting marks occur in the sub-micron depth. The rake angle of diamond tool is -35 and -65 degrees. Workpiece is synthetic silica glass. As an experimental result, the vibration-assisted cutting of the silica glass has a larger ductile-mode surface at removal depth of cut 0.09-0.15μm. And, it guessed that this increase of ductile-mode surface is affected by plastic flow of the workpiece under the tool, and ease of cut into workpiece by movement of cutting tool.