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Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate

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Abstract

Diamond cutting is a popular method to fabricate microlens array (MLA) on polymethyl methacrylate (PMMA); however, it is limited by brittle fracture, which is formed easily on the surface of MLA during the cutting process. In this paper, the formation mechanism of the brittle fracture is studied via a series of experiments including the slow tool servo (STS) cutting experiment of MLA, surface scratching experiment and sudden-stop cutting experiment. The effects of undeformed chip thickness, feed rate, and machining track on brittle fracture formation are investigated in detail. In addition, based on the fracture formation mechanism, a bi-directional cutting approach is proposed to eliminate the regional brittle fracture of the microlens during diamond cutting. An experiment was then conducted to verify the method; the results demonstrated that bi-directional cutting could eliminate brittle fracture entirely. Finally, a spherical MLA with the form error (vPV) of 60 nm and the surface roughness (Ra) of 8 nm was successfully fabricated.

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Acknowledgements

This work was financially supported by the National Key Basic Research Program of China (Grant No. 2015CB059900) and the National Natural Science Foundation of China (Grant No. 51775046). The authors would also like to acknowledge the support from the Fok Ying-Tong Education Foundation for Young Teachers in the Higher Education Institutions of China (Grant No. 151052).

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Authors and Affiliations

  1. Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing, 100081, People’s Republic of China

    Tian-Feng Zhou, Zhi-Qiang Liang & Xi-Bin Wang

  2. School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, People’s Republic of China

    Ben-Shuai Ruan, Jia Zhou & Xiao-Bin Dong

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  1. Tian-Feng Zhou
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  2. Ben-Shuai Ruan
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  3. Jia Zhou
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  5. Zhi-Qiang Liang
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Correspondence to Tian-Feng Zhou.

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Zhou, TF., Ruan, BS., Zhou, J. et al. Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate. Adv. Manuf. 7, 228–237 (2019). https://doi.org/10.1007/s40436-019-00260-7

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  • DOI: https://doi.org/10.1007/s40436-019-00260-7

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