Realization of High Efficiency and Low Damage Machining of Anisotropic KDP Crystal by Grinding

Meina Qu; Guizhi  Xie; Tan Jin; Rui Cai; Ange Lu

doi:10.1016/j.precisioneng.2018.10.016

Realization of High Efficiency and Low Damage Machining of Anisotropic KDP Crystal by Grinding

Meina Qu, Guizhi Xie, Tan Jin, Rui Cai, Ange Lu

Hunan University

Research output: Contribution to journal › Article › peer-review

22 Citations (Scopus)

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Abstract

Potassium dihydrogen phosphate (KDP) is a non-linear material used in various opto-electronic applications including Q-switches, high-speed photography shutters, frequency harmonic generation lens and Pockels cells in the Inertial Confinement Fusion (ICF) devices. KDP belongs to the most difficult-to-cut material, due to its delicate and unique characteristics including the combination of softness with brittleness, anisotropic performances, tendency for deliquescence and sensitivity to temperature change. Single point diamond turning (SPDT) is considered to be the ideal method for machining KDP components. However, the process efficiency is rather low and often accompanied with severe tool wear issues. This paper studies the feasibility using grinding method to remove the surface material of KDP components with high process efficiency and low damage, fulfilling the task of re-aligning the surface orientation to the crystalline axis. The grinding tests were carried out on a common CNC grinder, using resin bonded diamond grinding wheel, whilst the diamond abrasives are coated with Ni-P alloy. The direction of precision grinding was determined by studying the anisotropy of KDP, including its elastic modulus E, Vickers hardness HV and fracture toughness KIC, to reduce the influence of material anisotropy on machining quality. The grinding process parameters were preliminarily determined based on the experimental results investigating the effects of peripheral speed of the grinding wheel, worktable feed rate and grinding depth on the ground surface roughness. The surface defects, surface morphology and sub-surface damage under different process parameters were investigated. Surface roughness Ra ≤ 0.3 μm and sub-surface damage depth SSD ≤ 6 μm were obtained. The machining efficiency can be improved by nearly ten times using the proposed precision grinding method, producing nearly the same surface quality (Ra ≤ 0.2 μm, SSD ≤ 6 μm) as that in the axis fixing phase in SPDT.

Original language	English
Pages (from-to)	464-473
Number of pages	10
Journal	Precision Engineering
Volume	55
Early online date	5 Nov 2018
DOIs	https://doi.org/10.1016/j.precisioneng.2018.10.016
Publication status	Published - Jan 2019

Bibliographical note

NOTICE: this is the author’s version of a work that was accepted for publication in Precision Engineering. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control
mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Precision Engineering, 2018

DOI:10.1016/j.precisioneng.2018.10.016 © 2017, Elsevier. Licensed under the Creative Commons AttributionNonCommercial-NoDerivatives
4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/

Keywords

Crystal axis fixing
Grinding
KDP crystal
Machining efficiency
Sub-surface damage
Typical impurities embedded

ASJC Scopus subject areas

Engineering(all)

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10.1016/j.precisioneng.2018.10.016

Post-PrintAccepted author manuscript, 1.67 MBLicence: CC BY-NC-ND

Cite this

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title = "Realization of High Efficiency and Low Damage Machining of Anisotropic KDP Crystal by Grinding",

abstract = "Potassium dihydrogen phosphate (KDP) is a non-linear material used in various opto-electronic applications including Q-switches, high-speed photography shutters, frequency harmonic generation lens and Pockels cells in the Inertial Confinement Fusion (ICF) devices. KDP belongs to the most difficult-to-cut material, due to its delicate and unique characteristics including the combination of softness with brittleness, anisotropic performances, tendency for deliquescence and sensitivity to temperature change. Single point diamond turning (SPDT) is considered to be the ideal method for machining KDP components. However, the process efficiency is rather low and often accompanied with severe tool wear issues. This paper studies the feasibility using grinding method to remove the surface material of KDP components with high process efficiency and low damage, fulfilling the task of re-aligning the surface orientation to the crystalline axis. The grinding tests were carried out on a common CNC grinder, using resin bonded diamond grinding wheel, whilst the diamond abrasives are coated with Ni-P alloy. The direction of precision grinding was determined by studying the anisotropy of KDP, including its elastic modulus E, Vickers hardness HV and fracture toughness KIC, to reduce the influence of material anisotropy on machining quality. The grinding process parameters were preliminarily determined based on the experimental results investigating the effects of peripheral speed of the grinding wheel, worktable feed rate and grinding depth on the ground surface roughness. The surface defects, surface morphology and sub-surface damage under different process parameters were investigated. Surface roughness Ra ≤ 0.3 μm and sub-surface damage depth SSD ≤ 6 μm were obtained. The machining efficiency can be improved by nearly ten times using the proposed precision grinding method, producing nearly the same surface quality (Ra ≤ 0.2 μm, SSD ≤ 6 μm) as that in the axis fixing phase in SPDT.",

keywords = "Crystal axis fixing, Grinding, KDP crystal, Machining efficiency, Sub-surface damage, Typical impurities embedded",

author = "Meina Qu and Guizhi Xie and Tan Jin and Rui Cai and Ange Lu",

note = "NOTICE: this is the author{\textquoteright}s version of a work that was accepted for publication in Precision Engineering. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Precision Engineering, 2018 DOI:10.1016/j.precisioneng.2018.10.016 {\textcopyright} 2017, Elsevier. Licensed under the Creative Commons AttributionNonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/ ",

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AU - Qu, Meina

AU - Xie, Guizhi

AU - Jin, Tan

AU - Cai, Rui

AU - Lu, Ange

N1 - NOTICE: this is the author’s version of a work that was accepted for publication in Precision Engineering. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Precision Engineering, 2018 DOI:10.1016/j.precisioneng.2018.10.016 © 2017, Elsevier. Licensed under the Creative Commons AttributionNonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/

PY - 2019/1

Y1 - 2019/1

N2 - Potassium dihydrogen phosphate (KDP) is a non-linear material used in various opto-electronic applications including Q-switches, high-speed photography shutters, frequency harmonic generation lens and Pockels cells in the Inertial Confinement Fusion (ICF) devices. KDP belongs to the most difficult-to-cut material, due to its delicate and unique characteristics including the combination of softness with brittleness, anisotropic performances, tendency for deliquescence and sensitivity to temperature change. Single point diamond turning (SPDT) is considered to be the ideal method for machining KDP components. However, the process efficiency is rather low and often accompanied with severe tool wear issues. This paper studies the feasibility using grinding method to remove the surface material of KDP components with high process efficiency and low damage, fulfilling the task of re-aligning the surface orientation to the crystalline axis. The grinding tests were carried out on a common CNC grinder, using resin bonded diamond grinding wheel, whilst the diamond abrasives are coated with Ni-P alloy. The direction of precision grinding was determined by studying the anisotropy of KDP, including its elastic modulus E, Vickers hardness HV and fracture toughness KIC, to reduce the influence of material anisotropy on machining quality. The grinding process parameters were preliminarily determined based on the experimental results investigating the effects of peripheral speed of the grinding wheel, worktable feed rate and grinding depth on the ground surface roughness. The surface defects, surface morphology and sub-surface damage under different process parameters were investigated. Surface roughness Ra ≤ 0.3 μm and sub-surface damage depth SSD ≤ 6 μm were obtained. The machining efficiency can be improved by nearly ten times using the proposed precision grinding method, producing nearly the same surface quality (Ra ≤ 0.2 μm, SSD ≤ 6 μm) as that in the axis fixing phase in SPDT.

AB - Potassium dihydrogen phosphate (KDP) is a non-linear material used in various opto-electronic applications including Q-switches, high-speed photography shutters, frequency harmonic generation lens and Pockels cells in the Inertial Confinement Fusion (ICF) devices. KDP belongs to the most difficult-to-cut material, due to its delicate and unique characteristics including the combination of softness with brittleness, anisotropic performances, tendency for deliquescence and sensitivity to temperature change. Single point diamond turning (SPDT) is considered to be the ideal method for machining KDP components. However, the process efficiency is rather low and often accompanied with severe tool wear issues. This paper studies the feasibility using grinding method to remove the surface material of KDP components with high process efficiency and low damage, fulfilling the task of re-aligning the surface orientation to the crystalline axis. The grinding tests were carried out on a common CNC grinder, using resin bonded diamond grinding wheel, whilst the diamond abrasives are coated with Ni-P alloy. The direction of precision grinding was determined by studying the anisotropy of KDP, including its elastic modulus E, Vickers hardness HV and fracture toughness KIC, to reduce the influence of material anisotropy on machining quality. The grinding process parameters were preliminarily determined based on the experimental results investigating the effects of peripheral speed of the grinding wheel, worktable feed rate and grinding depth on the ground surface roughness. The surface defects, surface morphology and sub-surface damage under different process parameters were investigated. Surface roughness Ra ≤ 0.3 μm and sub-surface damage depth SSD ≤ 6 μm were obtained. The machining efficiency can be improved by nearly ten times using the proposed precision grinding method, producing nearly the same surface quality (Ra ≤ 0.2 μm, SSD ≤ 6 μm) as that in the axis fixing phase in SPDT.

KW - Crystal axis fixing

KW - Grinding

KW - KDP crystal

KW - Machining efficiency

KW - Sub-surface damage

KW - Typical impurities embedded

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DO - 10.1016/j.precisioneng.2018.10.016

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JO - Precision Engineering

JF - Precision Engineering

ER -

Realization of High Efficiency and Low Damage Machining of Anisotropic KDP Crystal by Grinding

Abstract

Bibliographical note

Keywords

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Rui Cai

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Realization of High Efficiency and Low Damage Machining of Anisotropic KDP Crystal by Grinding

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

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Rui Cai

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