Handbook of Advanced Ceramics Machining

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ISBN: 9780849338373 | 0849338379
Cover: Hardcover
Copyright: 11/16/2006

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Ceramics, with their unique properties and diverse applications, hold the potential to revolutionize many industries, including automotive and semiconductors. For many applications, ceramics could replace metals and other materials that are more easily and inexpensively machined. However, current ceramic machining methods remain cost-prohibitive. Fortunately, the current flurry of research will soon yield new and better methods for machining advanced ceramic materials.Reflecting the life-long dedication of an unsurpassed team of experts from industry and academia, the Handbook of Advanced Ceramics Machining explores the latest developments in our understanding of the mechanisms involved in ceramics machining as well as state-of-the-art technologies. Multiple chapters are devoted to various types and aspects of the lapping and grinding processes, such as mechanisms, monitoring techniques, mono- versus polycrystalline abrasives, and tribological properties. Covering methods that offer high-rate material removal and others that provide extremely high-quality surface finish, this book examines conventional, new, and lesser-known methods including ductile grinding, belt centerless grinding, lapping, polishing, double-side grinding, laser-assisted grinding, ultrasonic machining, and the new electrolytic in-process dressing (ELID) grinding method.An indispensable toolkit for opening new avenues of possibility for ceramics applications, the Handbook of Advanced Ceramics Machining helps bring cost-effective, high-performance, and high-precision methods into standard practice.

1. Ductile Grinding of Ceramics: Machine Tool and Process

(28)

H. Eda

1.1 Ceramics and Metals

(3)

1.2 Brittle Materials and Grinding

(5)

1.3 In-Site Observation of Ductile Behavior in Ceramics

(6)

1.3.1 Scratch at the Brittle-Mode

(1)

1.3.2 In-Site Observation of the Ductile Mode

(5)

1.4 Ductile-Mode Grinding of Ceramics

(3)

1.5 Machine Tools for Ductile Grinding of Ceramics

(3)

1.5.1 Design Criteria of Ductile Microgrinding Machine Tool

(3)

1.5.2 Key Technologies of a Ductile Microgrinding Machine Tool

(7)

References

(1)

2. Ductile-Mode Ultra-Smoothness Grinding of Fine Ceramics with Coarse-Grain-Size Diamond Wheels

(26)

H. Yasui

2.1 Introduction

(1)

2.2 Ductile-Mode Grinding with #140 Mesh Wheel

(16)

2.2.1 Experimental Procedure

(2)

2.2.2 Influence of the Table Speed

(7)

2.2.3 Influence of the Wheel Speed

(4)

2.2.4 Influence of the Workpiece Material

(3)

2.3 Ultra-smoothness Grinding

(5)

2.3.1 Ultra-smoothness Grinding Method

(3)

2.3.2 Ultra-smoothness Grinding Results

(2)

2.4 Conclusion

(2)

References

(2)

3. Mechanisms for Grinding of Ceramics

(32)

S. Malkin and T.W. Hwang

3.1 Introduction

(1)

3.2 Indentation Fracture Mechanics Approach

(11)

3.2.1 Median/Radial Cracks: Static Indentor

(5)

3.2.2 Median/Radial Cracks: Moving Indentor

(3)

3.2.3 Lateral Cracking and Crushing

(2)

3.3 Machining Approach

(14)

3.3.1 Grinding Debris

(1)

3.3.2 Microscopy of Scratches and Ground Surfaces

(3)

3.3.3 Grinding Energy and Mechanisms

(20)

3.3.3.1 Specific Grinding Energy

(2)

3.3.3.2 Brittle Fracture Energy

(4)

3.3.3.3 Plowed Surface Area Analysis

(1)

3.3.3.4 Plowed Surface Energy and Workpiece Properties

(2)

3.4 Concluding Remarks

(2)

References

(4)

4. Grinding of Ceramics with Attention to Strength and Depth of Grinding Damage

(22)

J.E. Mayer Jr.

Abstract

(1)

4.1 Introduction

(2)

4.2 Ceramic Materials

(1)

4.3 Experimental Procedure

(6)

4.3.1 Grinding

(1)

4.3.2 Grit Depth of Cut

(1)

4.3.3 Strength Testing

(1)

4.3.4 Lapping

(1)

4.3.5 Grinding Procedure for Determining Ground Strength

(1)

4.3.6 Grinding Procedure for Determining Damage Depth

(2)

4.4 Results and Discussion

(9)

4.4.1 Ground Strength

(5)

4.4.1.1 HPSN Ceramic

(1)

4.4.1.2 RBSN Ceramic

(2)

4.4.1.3 Other Ceramics

(2)

4.4.1.4 Guidelines for Efficient High-Strength Finish Grinding

101

(1)

4.4.1.5 Physical Meaning of Critical Grit Depth of Cut

101

(1)

4.4.2 Depth of Damage

101

(12)

4.4.2.1 RBSN Ceramic

101

(1)

4.4.2.2 Zirconia-Toughened Alumina Ceramic

102

(3)

4.4.2.3 Strategy for Minimum Grinding Time

105

(1)

4.5 Conclusions

105

(1)

References

106

(3)

5. Highly Efficient and Ultraprecision Fabrication of Structural Ceramic Parts with the Application of Electrolytic In-Process Dressing Grinding

109

(38)

B.P. Bandyopadhyay, H. Ohmori, and A. Makinouchi

Summary

110

(1)

Key Words

110

(1)

5.1 Introduction

111

(2)

5.2 ELID Grinding Principle

113

(5)

5.2.1 Electrodischarge Truing Technique

115

(2)

5.2.2 Electrical Behavior during Predressing

117

(1)

5.2.3 ELID Grinding Mechanism

118

(1)

5.3 Experimental Setup

118

(4)

5.3.1 Grinding Wheels

120

(1)

5.3.2 Grinding Fluid

120

(1)

5.3.3 Power Supply

121

(1)

5.3.4 Materials

121

(1)

5.3.5 Measuring Instrument Used

121

(1)

5.4 Results and Discussions

122

(20)

5.4.1 Influence of Bond Material

122

(2)

5.4.2 Influence of Power Source

124

(1)

5.4.3 Comparison between Conventional and ELID Grinding

125

(2)

5.4.4 Modified ELID Dressing Grinding

127

(3)

5.4.5 Grinding with Bronze and Cobalt-Bonded Wheels

130

(1)

5.4.6 Investigation of Grinding Ratio

130

(4)

5.4.7 Efficient Cylindrical Grinding on a Turning Center

134

(1)

5.4.8 Ultraprecision Grinding with ELID

135

(4)

5.4.8.1 SEM and AFM Studies

138

(1)

5.4.9 Flexural Strength of Silicon Nitride

139

(3)

5.5 Conclusions

142

(1)

5.6 Acknowledgments

143

(1)

References

143

(4)

6. Electrolytic In-Process Dressing Grinding of Ceramic Materials

147

(32)

H. Ohmori and K. Katahira

Abstract

148

(1)

Key Words

148

(1)

6.1 Introduction

148

(1)

6.2 ELID Grinding Technique

149

(6)

6.2.1 The Concept of ELID

149

(2)

6.2.2 ED Truing Technique

151

(1)

6.2.3 Electrical Behavior during Predressing

151

(3)

6.2.4 The ELID Grinding Mechanism

154

(1)

6.3 Efficient and Precision ELID Centerless Grinding of Zirconia Ceramics

155

(5)

6.3.1 Experimental Setup for ELID Centerless Grinding of Zirconia Ceramics

155

(2)

6.3.2 Results of ELID Centerless Grinding of Zirconia Ceramics

157

(3)

6.4 ELID Grinding Characteristics for the Machining of Optical Surface Quality for Ceramic Spherical Lens Molds

160

(4)

6.4.1 Mechanism of ELID CG-Grinding

160

(2)

6.4.2 Experimental Setup for ELID CG-Grinding

162

(1)

6.4.3 ELID CG-Grinding of Ceramic Spherical Lens Molds

162

(2)

6.5 ELID Grinding Characteristics and Surface Modifying Effects of Aluminum Nitride Ceramics

164

(12)

6.5.1 Experimental Setup for ELID Grinding of A1N Ceramics

164

(3)

6.5.2 Observation of the ELID Ground Surface

167

(1)

6.5.3 Surface Modifying Effect by ELID Grinding

168

(6)

6.5.4 Analysis of the Modified Surface

174

(2)

Acknowledgments

176

(1)

References

176

(3)

7. High-Efficiency Belt Centerless Grinding of Ceramic Materials and Hardened Tool Steel

179

(14)

G. Dontu, D. Wu, and I.D. Marinescu

7.1 Introduction

179

(2)

7.2 Definition of the Problem

181

(1)

7.3 Objectives

182

(1)

7.4 Experiments for Ceramic Materials

183

(1)

7.5 Results

184

(6)

7.6 Preliminary Conclusions

190

(1)

7.7 Experimental Plan for M7 Hardened Tool Steel Drill Bar

190

(1)

7.8 The Problem Encountered and Possible Reasons

191

(1)

7.9 Remaining Work

191

(1)

7.10 Benefits to Companies

192

(1)

7.11 Related Work Outside AMMC

192

(1)

7.12 Related Work Inside AMMC

192

(1)

8. AE Monitoring of the Lapping Process

193

(10)

M. Pruteanu, R. Conran, and I.D. Marinescu

8.1 Introduction

193

(1)

8.2 Related Work

194

(1)

8.2.1 Within University of Toledo

194

(1)

8.2.2 Outside AMMC

194

(1)

8.3 Methodology

195

(2)

8.4 Experimental Results

197

(4)

8.4.1 Experimental Procedure

197

(1)

8.4.2 Data Analysis

197

(7)

8.4.2.1 Energy Per Unit Time

198

(3)

8.5 Conclusions

201

(1)

8.6 Remaining Work

201

(2)

9. Effectiveness of ELID Grinding and Polishing

203

(44)

C.E. Spanu and I.D. Marinescu

9.1 Introduction

204

(9)

9.1.1 Principle and Mechanism of ELID Grinding

204

(2)

9.1.2 Components of ELID Grinding System

206

(2)

9.1.3 Electrical Aspects of ELID Grinding

208

(1)

9.1.4 Characteristics of Grinding Wheel in ELID Applications

209

(2)

9.1.5 Structure and Properties of Ceramics

211

(1)

9.1.6 ELID Grinding Applied to Various Materials

211

(1)

9.1.7 ELID Grinding Applied to Ceramic Materials

212

(1)

9.2 Material Removal Mechanisms in Grinding of Ceramics and Glasses

213

(3)

9.3 ELID Technique as Compared to Other Grinding Techniques

216

(2)

9.3.1 Summary of ELID Technology

216

(2)

9.3.2 Other In-Process Dressing Technologies

218

(1)

9.4 Applications of ELID Technique

218

(26)

9.4.1 ELID-Side Grinding

219

(1)

9.4.2 ELID Double-Side Grinding

220

(2)

9.4.3 ELID-Lap Grinding

222

(3)

9.4.4 ELID Grinding of Ceramics on Vertical Rotary Surface Grinder

225

(1)

9.4.5 ELID Grinding of Ceramics on Vertical Grinding Center

226

(4)

9.4.6 ELID Grinding of Bearing Steels

230

(4)

9.4.7 ELID Grinding of Ceramic Coatings

234

(1)

9.4.8 ELID Ultraprecision Grinding of Aspheric Mirror

235

(2)

9.4.9 ELID Grinding of Microspherical Lenses

237

(1)

9.4.10 ELID Grinding of Large Optical Glass Substrates

237

(1)

9.4.11 ELID Precision Internal Grinding

237

(3)

9.4.12 ELID Grinding of Hard Steels

240

(1)

9.4.13 ELID Mirror-Like Grinding of Carbon Fiber Reinforced Plastics

241

(1)

9.4.14 ELID Grinding of Chemical Vapor Deposited Silicon Carbide

242

(1)

9.5 Summary and Conclusions

242

(2)

References

244

(3)

10. Mono- Versus Polycrystalline Diamond Lapping of Ceramics

247

(1)

M. Pruteanu, I. Benea, and I.D. Marinescu

10.1 Introduction

247

(1)

10.2 Experimental Methodology

248

(1)

10.3 Experimental Results

249

(6)

10.4 Remaining Work

255

(1)

References

256

(1)

11. Double Fracture Model in Lapping of Ceramics

257

(1)

I.D. Marinescu

11.1 Introduction

257

(1)

11.2 Double Fracture Model

258

(1)

11.3 Experimental Procedures

258

(3)

11.3.1 Materials

258

(2)

11.3.2 Apparatus

260

(1)

11.3.3 Methodology

261

(1)

11.4 Conclusions

261

(2)

12. Double Side Grinding of Advanced Ceramics with Diamond Wheels

263

(1)

C.E. Spanu, Marinescu, and M. Hitchiner

Abstract

263

(1)

12.1 Introduction

264

(1)

12.2 Kinematical Model for the Double Side Grinding Operation

265

(6)

12.3 Trajectory Simulation

271

(4)

12.4 Experimental Validation

275

(2)

12.5 Discussion of Results

277

(3)

12.6 Conclusions

280

(1)

References

281

(2)

13. Super Polishing of Magnetic Heads

283

(1)

J. Ramirez-Salas and I.D. Marinescu

13.1 Introduction

283

(1)

13.2 Related Work

284

(1)

13.2.1 Inside University of Toledo

284

(1)

13.2.2 Outside PMMC

284

(1)

13.3 Methodology

285

(1)

13.4 Experimental Results

286

(1)

13.4.1 Material Removal

286

(1)

13.4.2 Roughness and Profile

287

(1)

13.5 Remaining Work

287

(6)

14. Laser-Assisted Grinding of Ceramics

293

(1)

I.D. Marinescu, T.D. Howes and J. Webster

14.1 Objectives

293

(1)

14.2 Problem Statement

294

(3)

14.2.1 Introduction

294

(1)

14.2.2 Experimental Setup

294

(1)

14.2.3 Results and Discussions

295

(2)

14.3 Stock Removal Mechanism

297

(2)

14.4 Conclusions

299

(1)

14.5 Future Directions

299

(1)

Bibliography

299

(2)

15. Tribological Properties of ELID-Grinding Wheel Based on In-Process Observation Using a CCD Microscope Tribosystem

301

(1)

T. Kato, H. Ohmori, and I.D. Marinescu

15.1 Introduction

301

(2)

15.2 Experimental Method

303

(1)

15.3 Experimental Result and Discussion

304

(3)

15.3.1 Wear Mode of Abrasive-Grinding Wheel

304

(1)

15.3.2 Wear Property of Sapphire Pin

305

(1)

15.3.3 Friction Property

305

(2)

15.3.4 Wear Property

307

(1)

15.4 Consideration for ELID-Grinding from the Viewpoint of Tribology

307

(4)

15.5 Conclusions

311

(1)

References

312

(1)

16. Developments in Machining of Ceramic Materials

313

(1)

E. Uhlmann, S.-E. Holl, Th. Ardelt, and J. Laufer

16.1 Introduction

313

(2)

16.2 Honing

315

(2)

16.2.1 General Information

315

(1)

16.2.2 Technological Investigations

316

(1)

16.2.3 Influence of Material and Structural Properties

317

(1)

16.3 Grinding with Lapping Kinematics

317

(3)

16.3.1 Process Technology

317

(1)

16.3.2 Machining Process

318

(1)

16.3.3 Application and Prospect

318

(2)

16.4 Cooling Lubrication in Grinding of Ceramic Materials

320

(5)

16.4.1 General Facts

320

(1)

16.4.2 Selecting the Cooling Lubricant

320

(4)

16.4.2.1 Technological Aspects of the Selection

320

(3)

16.4.2.2 Physiological, Ecological, and Economic Aspects

323

(1)

16.4.3 Design of the Feed System

324

(1)

16.4.4 Design of the Cleaning System

324

(1)

References

325

(2)

17. Ultrasonic Machining of Ceramics

327

(1)

G. Spur, E. Uhlmann, S.-E. Ho11, and N.-A. Daus

17.1 Introduction

327

(1)

17.2 Ultrasonic Technology

328

(2)

17.3 Technology of Ultrasonic Lapping

330

(12)

17.3.1 Fundamentals

330

(4)

17.3.2 Machinability of Ceramic Materials

334

(1)

17.3.3 Conventional Face Die-Sinking

335

(4)

17.3.3.1 Vibrational Amplitude

336

(2)

17.3.3.2 Lapping Pressure

338

(1)

17.3.3.3 Abrasive

338

(1)

17.3.3.4 Wear of the Shape-Generating Counterpart

339

(1)

17.3.4 Conventional Face Die-Sinking with Rotational Superposition

339

(2)

17.3.5 Path Machining

341

(1)

17.4 Ultrasonic-Assisted Grinding

342

(8)

17.4.1 Fundamentals

342

(2)

17.4.2 Machinability of Ceramic Materials

344

(1)

17.4.3 Surface Grinding

345

(1)

17.4.4 Face Grinding

346

(2)

17.4.4.1 Tool-Path-Controlled Feed Speed

347

(1)

17.4.4.2 Force-Controlled Feed Speed

348

(1)

17.4.5 Cross-Peripheral Grinding

348

(2)

17.5 Process Comparison

350

(1)

References

350

(5)

Index

355

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Handbook of Advanced Ceramics Machining

Summary

Table of Contents

Supplemental Materials