Experimental investigation of temperature in the cutting zone in microgrinding

At a Glance

Metadata	Details
Publication Date	2017-01-01
Journal	Bulletin of the South Ural State University series Mechanical Engineering Industry
Authors	A. A. D’yakonov, Anastasia E. Gorodkova
Analysis	Full AI Review Included

EXPERIMENTAL INVESTIGATION OF TEMPERATURE IN THE CUTTING ZONE IN MICROGRINDING

(Technical Analysis & Sales Documentation by 6CCVD Engineering Team)

Executive Summary

This research utilizes advanced diamond tooling to develop and validate a crucial thermophysical model for microgrinding, directly addressing the need for non-empirical, scalable manufacturing processes.

Core Achievement: Successful experimental verification and calibration of a thermophysical model designed to predict temperature distribution during microgrinding.
Material Choice: The study confirms Polycrystalline Diamond (PCD) as the necessary cutting material for high-precision micro-mechanical processing of demanding optical materials (K-8 grade glass).
Precision Methodology: Utilizes a unique measurement system combining a Kistler dynamometer for force and an SC7000 thermal imager for highly localized, pixel-based temperature mapping in the cutting zone.
Thermal Dynamics Captured: Data establishes a non-linear relationship between material feed rate (25 to 45 µm/min) and cutting zone temperature, essential for process optimization.
Tooling Insight: The experiments quantified the critical tool run-in period, identifying the time required for temperature stabilization—a key factor for maintaining high geometric accuracy and extending tool life.
Application Relevance: The results are foundational for developing a robust computational package to simulate and define optimal, high-volume machining recipes for micro-components in electronics and medical devices.

Technical Specifications

The following hard parameters define the experimental microgrinding process, emphasizing the requirements for high-precision PCD tooling and sub-micron depth control.

Parameter	Value	Unit	Context
Tool Material	Polycrystalline Diamond (PCD)	N/A	Cutting edge material for microgrinding
Workpiece Material	K-8 Glass	N/A	Target material for optical/medical components
Tool Diameter	0.7	mm	Diameter of the PCD cutting element
Cut Depth ($a_{p}$)	2	µm	Depth of the ground channel (Micro-scale resolution)
Channel Width	0.7	mm	Width of the machined groove
Channel Length	1.5	mm	Total distance of the grinding pass
Spindle Speed ($N$)	2000	rpm	Fixed frequency of rotation
Feed Rate ($V_{f}$) Range	25 - 45	µm/min	Experimental range for investigating thermal effects
Maximum Temp. Differential	Up to 5	°C	Temperature increase observed between 25 and 35 µm/min feed
K-8 Glass Emissivity	0.9 - 0.95	N/A	Required range for accurate thermal imaging

Key Methodologies

The experimental approach focused on isolating and precisely measuring thermal and mechanical factors during microgrinding using state-of-the-art metrology and highly controlled cutting conditions.

Machine Setup: Experiments conducted on a specialized Mikrotool DT-110 machine featuring high-precision linear movement capabilities.
Tooling Selection: Polycrystalline Diamond (PCD) tools with a precise diameter of 0.7 mm were utilized, reflecting the necessity of highly durable and sharp abrasive materials for micro-machining brittle substances.
Mechanical Measurement: Cutting forces were monitored continuously using a high-sensitivity Kistler dynamometer.
Thermal Measurement (Unique Technique):
- Temperature was recorded using an SC7000 thermal imager, selected for its ability to measure temperatures in the high-emissivity K-8 glass.
- Data processing was performed in Matlab, mapping temperature values to specific pixels, thus correlating temperature precisely to the distance from the cutting edge in the workpiece.
Grinding Recipe: Channels were ground with fixed parameters: 0.7 mm width and 2 µm depth.
Operational Parameters: The process was investigated across three primary feed rates (25, 35, and 45 µm/min) while maintaining a constant spindle speed of 2000 rpm.
Data Analysis: Temperature readings were taken at the start, middle, and end of each channel to track thermal stabilization associated with tool run-in.

6CCVD Solutions & Capabilities

6CCVD is uniquely positioned to supply the advanced MPCVD diamond materials necessary to replicate, expand upon, and scale the microgrinding processes investigated in this research. Our capabilities ensure the highly uniform, durable, and customized tooling required for predictive thermal modeling and high-precision manufacturing.

Applicable Materials

The foundation of this research is the high thermal stability and hardness of diamond tooling. 6CCVD recommends specialized Polycrystalline Diamond (PCD) for microgrinding applications.

PCD (Polycrystalline Diamond): Essential for microgrinding glass and ceramics due to superior wear resistance and hardness. We offer PCD in thicknesses from 0.1 µm up to 500 µm, allowing engineers to select the optimal layer for tool design integrity and thermal performance.
- Recommendation: High-Grade MPCVD PCD, optimized for uniform grain size (available in varying grades to match desired roughness and wear rates).
SCD (Single Crystal Diamond): For ultra-high precision applications or when an even lower surface roughness (Ra < 1 nm) is required on the final tool geometry, custom SCD plates can be utilized for specialized micro-tools.

Customization Potential for Micro-Tooling

Replicating the 0.7 mm diameter micro-tool used in this study requires exceptional precision and customization, areas where 6CCVD excels.

Capability	Requirement Met	6CCVD Advantage
Custom Dimensions	Production of PCD blanks for 0.7 mm cutting tools.	We provide precision diamond wafers (up to 125 mm PCD) suitable for laser machining and integration into complex micro-tool holders.
Precision Shaping	Creating precise geometries required for micro-tool edges.	Utilizing advanced laser cutting and shaping services to create complex, sub-millimeter tool geometries from both PCD and SCD plates.
Surface Finish	Minimizing initial roughness to accelerate the “run-in” stabilization time observed in the paper.	Ultra-Polishing Services: Achieve surface roughness Ra < 5 nm on inch-size PCD, ensuring rapid thermal stabilization and predictable performance from the first cut.
Metalization	Needed for robust bonding of diamond elements to tool shanks/holders.	In-house Metalization: Custom thin-film metal layers (e.g., Ti/W/Au, Pt, Cu) applied directly to diamond surfaces for enhanced thermal management and mechanical adhesion.

Engineering Support & Sales Proposition

The thermal modeling approach described in this paper is a vital step toward reducing reliance on time-consuming empirical studies. 6CCVD supports clients in adopting this predictive methodology.

Materials Consultation: 6CCVD’s in-house PhD engineering team assists with material selection, optimizing diamond type (SCD vs. PCD) and layer thickness based on specific micro-tooling applications, such as high-thermal-load microgrinding.
Thermal Management Optimization: We provide diamond materials with tailored properties (e.g., specific nitrogen concentrations in SCD for customized thermal conductivity) that can directly input into advanced thermophysical models like the one validated in this research.
Global Supply Chain: We offer reliable global shipping (DDU default, DDP available) to ensure rapid delivery of customized diamond materials for critical R&D and production timelines worldwide.

For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.

View Original Abstract

The article describes the technique and results of experimental studies of micromechanical processing - microgrinding. The main goal of the conducted experiments is the approbation of the developed thermophysical model of microgrinding. This model avoids a large number of experiments with changing materials, technical requirements and production conditions. As the processed material, K-8 grade glass is chosen, which is the most popular material for manufacturing optical and medical devices, such as lenses, prisms, lasers, cuvettes for hemoglobins, etc. The material of the cutting part of the microgrinding tool is polycrystalline diamond. To collect data on cutting forces, the Kistler dynamometer was used. For research and collection of data on the cutting temperature, a unique technique was used, which makes it possible to obtain a thermal imager and image processing using pixels. This technique allows you to record the temperature at any time, and also clearly associate it with the known value of the pixel dimensions. During the experiments it was found that from the filing of feed, the processing time. It was found that the increase in feed rate leads to an increase in temperature, however, the character of the dependence is not linear. In addition, a certain time of running-in of the cutting tool, characterized by temperature stabilization. The nature of heat distribution in the workpiece is also revealed. The collected data allow to test the developed thermophysical model and to calibrate the computer program complex.

Tech Support

Original Source

DOI: https://doi.org/10.14529/engin170206