Skip to main content
SpringerLink
Log in

Research on the critical condition of Brittle-Ductile Transition about Micro-Milling of KDP crystal and experimental verification

  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

KDP crystal is a kind of brittle material, and improper selection of processing parameter can easily result in brittle domain cutting of KDP crystal. Determining the critical cutting depth of micro-milling brittle-ductile transition of KDP crystal can guide the selection of process parameters. The elastic-plastic contact formula of blunt spherical indenter and brittle materials is used to explicate the contact of micro-cutter edge and brittle materials. Combined with indentation critical load equation, the calculation model of predicting the critical cutting depth is established. The critical cutting depth is the function of material properties of the workpiece, the tool material properties and the tool edge radius. The edge radius of CBN flat end milling cutter is measured by atomic force microscopy, and then the critical cutting depth of the KDP crystal material is calculated as 230 nm. By using this milling cutter, microgroove milling experiments are conducted with different spindle speeds and feeds. The results demonstrate that as the spindle speed increases, the micro-groove bottom surface gradually transformed from the brittle cutting state to plastic cutting state. The critical spindle speed is 30000 rpm, and the maximum deformed cutting thickness is 227 nm, which coincides with the result of the theoretical calculation model.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Negres, R. A., Kucheyev, S. O., DeMange, P., Bostedt, C., Van Buuren, T., et al., “Decomposition of KH2PO4 Crystals during Laser-Induced Breakdown,” Applied Physics Letters, Vol. 86, No. 17, Paper No. 171107, 2005.

    Google Scholar 

  2. Zhang, K. C. and Wang, X. M., “Material Science of Nonlinear Optical Crystals,” Science Press, pp. 86–102, 1996.

    Google Scholar 

  3. De Yoreo, J. J., Burnham, A. K., and Whitman, P. K., “Developing KH2PO4 and KD2PO4 Crystals for the World's Most Power Laser,” International Materials Reviews, Vol. 47, No. 3, pp. 113–152, 2002.

    Article  Google Scholar 

  4. Norton, M. A., Hrubesh, L. W., Wu, Z., Donohue, E. E., Feit, M. D., et al., “Growth of Laser Initiated Damage in Fused Silica at 351 nm,” Proc. of SPIE, Vol. 4347, 2001.

  5. Demos, S. G., Kozlowski, M. R., Staggs, M. C., Chase, L. L., Burnham, A. K., and Radousky, H. B., “Mechanisms to Explain Damage Growth in Optical Materials,” Proc. of SPIE, Vol. 4347, 2000.

  6. Guillet, F., Bertussi, B., Lamaignere, L., Leborgne, X., and Minot, B., “Preliminary Results on Mitigation of Kdp Surface Damage using the Ball Dimpling Method,” Proc. of SPIE, Vol. 6720, Paper No. 672008, 2007.

  7. Hrubesh, L. W., Brusasco, R. M., Grundler, W., Norton, M. A., Donohue, E. E., et al., “Methods for Mitigating Growth of Laser-Initiated Surface Damage on DKDP Optics at 351 nm,” Proc. of SPIE, Vol. 4932, pp. 180–191, 2003.

    Article  Google Scholar 

  8. Suzuki, H., Moriwaki, T., Yamamoto, Y., and Goto, Y., “Precision Cutting of Aspherical Ceramic Molds with Micro PCD Milling Tool,” CIRP Annals-Manufacturing Technology, Vol. 56, No. 1, pp. 131–134, 2007.

    Article  Google Scholar 

  9. Wang, J., “Survey and Summary from DNA Biosensors to Gene Chips,” Nucleic Acids Research, Vol. 28, No. 16, pp. 3011–3016, 2000.

    Article  Google Scholar 

  10. Matsumura, T., Ono, T., and Takahashi, Y., “Effect of Tool Inclination on Machining of Tungsten Carbide with a CBN Ball End Mill,” Proc. of 34th NAMRC, pp. 95–102, 2006.

    Google Scholar 

  11. Arif, M., Rahman, M., San, W. Y., and Doshi, N., “An Experimental Approach to Study the Capability of End-Milling for Microcutting of Glass,” The International Journal of Advanced Manufacturing Technology, Vol. 53, No. 9–12, pp. 1063–1073, 2011.

    Article  Google Scholar 

  12. Matsumura, T. and Ono, T., “Cutting Process of Glass with Inclined Ball End mill,” Journal of Materials Processing Technology, Vol. 200, No. 1, pp. 356–363, 2008.

    Article  Google Scholar 

  13. Foy, K., Wei, Z., Matsumura, T., and Huang, Y., “Effect of Tilt Angle on Cutting Regime Transition in Glass Micromilling,” International Journal of Machine Tools and Manufacture, Vol. 49, No. 3, pp. 315–324, 2009.

    Article  Google Scholar 

  14. Ono, T. and Matsumura, T., “Influence of Tool Inclination on Brittle Fracture in Glass Cutting with Ball End Mills,” Journal of Materials Processing Technology, Vol. 202, No. 1, pp. 61–69, 2008.

    Article  Google Scholar 

  15. Ko, T. J. and Yoon, I. J., “Mill-Grinding with Electroplated Diamond Abrasives for Ceramic Cutting,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 1, pp. 5–10, 2012.

    Article  Google Scholar 

  16. Moola, M. R., Gorin, A., and Hossein, K. A., “Optimization of Various Cutting Parameters on the Surface Roughness of the Machinable Glass Ceramic with Two Flute Square End Mills of Micro Grain Solid Carbide,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 9, pp. 1549–1554, 2012.

    Article  Google Scholar 

  17. Bifano, T. G., Dow, T. A., and Scattergood, R. O., “Ductile-Regime Grinding: A New Technology for Machining Brittle Materials,” Journal of Manufacturing Science and Engineering, Vol. 113, No. 2, pp. 184–189, 1991.

    Google Scholar 

  18. Arif, M., Rahman, M., and San, W. Y., “Analytical Modeling of Ductile-Regime Machining of Tungsten Carbide by Endmilling,” The International Journal of Advanced Manufacturing Technology, Vol. 55, No. 1–4, pp. 53–64, 2011.

    Article  Google Scholar 

  19. Blake, P. N. and Scattergood, R. O., “Ductile — Regime Machining of Germanium and Silicon,” Journal of the American Ceramic Society, Vol. 73, No. 4, pp. 949–957, 1990.

    Article  Google Scholar 

  20. Zhang, Q., “Nano-Indentation of Cubic and Tetragonal Single Crystals,” University of Rochester, pp. 95–110, 2008.

    Google Scholar 

  21. Fang, T. and Lambropoulos, J. C., “Microhardness and Indentation Fracture of Potassium Dihydrogen Phosphate (KDP),” Journal of the American Ceramic Society, Vol. 85, No. 1, pp. 174–178, 2002.

    Article  Google Scholar 

  22. Lawn, B. and Wilshaw, R., “Indentation Fracture: Principles and Applications,” Journal of Materials Science, Vol. 10, No. 6, pp. 1049–1081, 1975.

    Article  Google Scholar 

  23. Lawn, B. R., “Fracture of Brittle Solids,” Cambridge University Press, pp. 251–257, 1975.

    Google Scholar 

  24. Lawn, B. R. and Marshall, D. B., “Hardness, Toughness, and Brittleness: An Indentation Analysis,” Journal of the American Ceramic Society, Vol. 62, No. 7–8, pp. 347–350, 1979.

    Article  Google Scholar 

  25. Xiao, Y., Chen, M., Chu, X., and Tian, W., “Research on Accuracy Analysis and Performance Verification Test of Micro-Precise Five-Axis Machine Tool,” The International Journal of Advanced Manufacturing Technology, Vol. 67, No. 1–4, pp. 387–395, 2013.

    Article  Google Scholar 

  26. Heath, P. J., “Properties and Uses of Amborite [Polycrystalline cBN],” Industrial Diamond Review, Vol. 46, No. 514, pp. 120–127, 1986.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Center for Precision Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Yong Xiao, Ming-Jun Chen, Yan-Ting Yang & Jian Cheng

Authors
  1. Yong Xiao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ming-Jun Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yan-Ting Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jian Cheng
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ming-Jun Chen.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Xiao, Y., Chen, MJ., Yang, YT. et al. Research on the critical condition of Brittle-Ductile Transition about Micro-Milling of KDP crystal and experimental verification. Int. J. Precis. Eng. Manuf. 16, 351–359 (2015). https://doi.org/10.1007/s12541-015-0046-9

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-015-0046-9

Keywords

Search

Navigation