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Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal

Potassium dihydrogen phosphate (KDP or KH(2)PO(4)) crystal is widely used as terminal frequency converters in inertial confinement fusion (ICF). However, KDP crystal is a typical difficult-to-cut optical crystal with the characteristic of soft-brittle. In this work, the relationship between cutting...

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Autores principales: Chen, Ni, Wu, Chunya, Chen, Mingjun, Li, Liang, He, Ning
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2018
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6266207/
https://www.ncbi.nlm.nih.gov/pubmed/30400612
http://dx.doi.org/10.3390/mi9110574
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author Chen, Ni
Wu, Chunya
Chen, Mingjun
Li, Liang
He, Ning
author_facet Chen, Ni
Wu, Chunya
Chen, Mingjun
Li, Liang
He, Ning
author_sort Chen, Ni
collection PubMed
description Potassium dihydrogen phosphate (KDP or KH(2)PO(4)) crystal is widely used as terminal frequency converters in inertial confinement fusion (ICF). However, KDP crystal is a typical difficult-to-cut optical crystal with the characteristic of soft-brittle. In this work, the relationship between cutting force and processed surface quality in micro ball end-milling of KDP crystal with various depth of cut and spindle speed is studied by carried out the micro-milling experiments. Fast Fourier Transform (FFT) algorithm is used to diagnose the recorded cutting force. The periodic change of cutting force and the cutting force after filtering noises can be got through FFT analysis. Through calculating the correlation coefficients between the static component of thrust force and roughness value Ra of machined grooves, as well as the peak-valley (P-V) value of thrust force and dimensional error of machined grooves, the roughness value Ra and dimensional error of machined grooves would be predicted by monitoring the static component and P-V value of the thrust force, respectively. The relatively large spindle speed helps to reduce the roughness value Ra. The spindle speed with moderate value is recommended to reduce the dimensional error of machined groove because the dimensional error of machined groove will increase when the spindle speed is small enough (causing brittle cutting) or large enough (reducing cutting stability).
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spelling pubmed-62662072018-12-06 Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal Chen, Ni Wu, Chunya Chen, Mingjun Li, Liang He, Ning Micromachines (Basel) Article Potassium dihydrogen phosphate (KDP or KH(2)PO(4)) crystal is widely used as terminal frequency converters in inertial confinement fusion (ICF). However, KDP crystal is a typical difficult-to-cut optical crystal with the characteristic of soft-brittle. In this work, the relationship between cutting force and processed surface quality in micro ball end-milling of KDP crystal with various depth of cut and spindle speed is studied by carried out the micro-milling experiments. Fast Fourier Transform (FFT) algorithm is used to diagnose the recorded cutting force. The periodic change of cutting force and the cutting force after filtering noises can be got through FFT analysis. Through calculating the correlation coefficients between the static component of thrust force and roughness value Ra of machined grooves, as well as the peak-valley (P-V) value of thrust force and dimensional error of machined grooves, the roughness value Ra and dimensional error of machined grooves would be predicted by monitoring the static component and P-V value of the thrust force, respectively. The relatively large spindle speed helps to reduce the roughness value Ra. The spindle speed with moderate value is recommended to reduce the dimensional error of machined groove because the dimensional error of machined groove will increase when the spindle speed is small enough (causing brittle cutting) or large enough (reducing cutting stability). MDPI 2018-11-05 /pmc/articles/PMC6266207/ /pubmed/30400612 http://dx.doi.org/10.3390/mi9110574 Text en © 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Chen, Ni
Wu, Chunya
Chen, Mingjun
Li, Liang
He, Ning
Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal
title Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal
title_full Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal
title_fullStr Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal
title_full_unstemmed Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal
title_short Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal
title_sort research on the relationship between cutting force and machined surface quality in micro ball end-milling of potassium dihydrogen phosphate crystal
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6266207/
https://www.ncbi.nlm.nih.gov/pubmed/30400612
http://dx.doi.org/10.3390/mi9110574
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