Investigation of the Ductile Cutting Behavior of Monocrystalline Yttria-stabilized Zirconia during Ultra-precision Orthogonal Cutting

다국어 초록 (Multilingual Abstract)

Manufacturability of advanced ceramics has been a challenging issue mainly because of their brittle behaviors and high hardness. One approach to solving this issue is enabling ductile regime cutting, which can also be used to enhance the quality of the surface and accuracy of the final product. There have been many studies investigating how to control and prolong the ductile response regime during cutting; however, it still lacks a straightforward explanation that enables us to predict the transition of the material response from the ductile regime to the brittle regime. In this study, the processing of monocrystalline yttria-stabilized zirconia was investigated to predict material behavior during cutting. Here, it is aimed to confirm that stress intensity factor analysis can be applied with a wide variety of process parameters and investigate the effect of varying the process parameters on the ductile–brittle material response transition. Experimental results showed that negative rake angle and higher cutting speed prolonged the ductile cutting regime. However, the cutting stress at the ductile–brittle transition point remained constant regardless of the process parameters which enabled us to predict the transition point with respect to the stress intensity factor. It is expected that the results of this research can contribute to the development of machining strategies with improved throughput and thus to increasing the utilization of ceramic materials.

참고문헌 (Reference)

• 1 Anselmi-Tamburini, U., "Transparent nanometric cubic and tetragonal zirconia obtained by high-pressure pulsed electric current sintering" 17 (17): 3267-3273, 2007
• 2 Hannink, R. H. J., "Transformation toughening in zirconia-containing ceramics" 83 (83): 461-487, 2000
• 3 Chen, J. B., "Theoretical study on brittle–ductile transition behavior in elliptical ultrasonic assisted grinding of hard brittle materials" 46 : 104-117, 2016
• 4 Yoon, H. -S., "Study of stress intensity factor on the anisotropic machining behavior of single crystal sapphire" 67 (67): 125-128, 2018
• 5 Kienzle, O., "Spezifi sche Schnittkräfte bei der Metallbearbeitung" 47 (47): 224-255, 1957
• 6 Ferraris, E., "Shaping of engineering ceramics by electro, chemical and physical processes" 65 (65): 761-784, 2016
• 7 Venkatachalam, S., "Predictive modeling of transition undeformed chip thickness in ductile-regime micro-machining of single crystal brittle materials" 209 (209): 3306-3319, 2009
• 8 Shan Luo, "Numerical Simulation of Chip Ploughing Volume in Micro Ball-End Mill Machining" 한국정밀공학회 18 (18): 915-922, 2017
• 9 Gaofeng Zhang, "Monitoring for Damage in Two-Dimensional Pre-Stress Scratching of SiC Ceramics" 한국정밀공학회 17 (17): 1425-1432, 2016
• 10 김창주, "Molecular Dynamics Simulations of Plastic Material Deformation in Machining with a Round Cutting Edge" 한국정밀공학회 13 (13): 1303-1309, 2012
• 11 Pajares, A., "Microhardness and fracture toughness anisotropy in cubic zirconium oxide single crystals" 71 (71): 332-333, 1988
• 12 Schelling, P. K., "Mechanism of the cubic-to-tetragonal phase transition in zirconia and yttriastabilized zirconia by molecular-dynamics simulation" 84 (84): 1609-1619, 2001
• 13 Philipp Maas, "Machinability Study of Single-Crystal Sapphire in a Ball- End Milling Process" 한국정밀공학회 18 (18): 109-114, 2017
• 14 Pfeff erkorn, F. E., "Laser-assisted machining of magnesia-partially-stabilized zirconia" 126 (126): 42-51, 2004
• 15 Z. Y. Liu, "Kinematic modeling and deformation mechanics in shot peening of functional ceramics" Springer Science and Business Media LLC 93 (93): 1669-1683, 2017
• 16 Günay, M., "Investigation of the eff ect of rake angle on main cutting force" 44 (44): 953-959, 2004
• 17 Mizumoto, Y., "Investigation of the cutting mechanisms and the anisotropic ductility of monocrystalline sapphire" 66 (66): 89-92, 2017
• 18 Yoon, H. -S., "Investigation of ductilebrittle transition in machining of yttrium-stabilized zirconia (YSZ)" 26 : 446-453, 2018
• 19 Chen, X., "Infl uence of cutting parameters on the ductile-brittle transition of single-crystal calcium fl uoride during ultra-precision cutting" 89 (89): 219-225, 2017
• 20 윤해성, "Geometric Optimization of Micro Drills using Taguchi Methods and Response Surface Methodology" 한국정밀공학회 12 (12): 871-875, 2011
• 21 Farzad Pashmforoush, "Experimentally Validated Finite Element Analysis for Evaluating Subsurface Damage Depth in Glass Grinding Using Johnson-Holmquist Model" 한국정밀공학회 18 (18): 1841-1847, 2017
• 22 Blake, P. N., "Ductile-regime machining of germanium and silicon" 73 (73): 949-957, 1990
• 23 Jiwang Yan, "Ductile regime turning at large tool feed" Elsevier BV 121 (121): 363-372, 2002
• 24 Jiunn-Jyh Junz Wang, "Critical Depth of Cut and Specific Cutting Energy of a Microscribing Process for Hard and Brittle Materials" ASME International 130 (130): 011002-011002–6, 2008
• 25 Niccolò Grossi, "Accurate and Fast Measurement of Specific Cutting Force Coefficients Changing with Spindle Speed" 한국정밀공학회 18 (18): 1173-1180, 2017
• 26 Wee Keong Neo, "A review on the current research trends in ductile regime machining" Springer Science and Business Media LLC 63 (63): 465-480, 2012
• 27 Arif, M., "A predictive model of the critical undeformed chip thickness for ductile–brittle transition in nano-machining of brittle materials" 64 : 114-122, 2013