Experimental Investigation on CO 2 Laser-Assisted Micro-Grinding Characteristics of Al 2 O 3
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International Journal of Precision Engineering and Manufacturing https://doi.org/10.1007/s12541-020-00446-1
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Experimental Investigation on CO2 Laser‑Assisted Micro‑Grinding Characteristics of Al2O3 Wooyong Kwon1 · Taekyum Kim2 · Ki Young Song3 Received: 20 April 2020 / Revised: 21 October 2020 / Accepted: 24 November 2020 © Korean Society for Precision Engineering 2020
Abstract Fabricating micro-scale features in ceramic materials, such as alumina (Al2O3), is challenging because of their high hardness and brittleness. Laser-assisted machining, in which a laser beam is a heat source for pre-softening the local area on a workpiece, is an effective hybrid method for machining ceramics. The study identified the effects of carbon dioxide (CO2) laser-assisted micro-grinding (LAMG) with a wire electrical discharge grinding polycrystalline diamond tool on A l 2O 3. Comprehensive investigations have been conducted on the effects of laser beam machining itself and the effect of machining parameters, such as laser beam power, axial depth of cut, and feed rate. The average grinding force was found to decrease by 46% in the thrust direction and 44% in the feed direction, and surface roughness decreased by 17% with LAMG. Moreover, machining at a higher feed rate was possible without tool fracture. The results indicate that the C O2 laser heating of A l 2O 3 has significant advantages over conventional methods regarding machinability and channel geometry. Finally, an improved LAMG process to prevent edge cracks by revising the machining conditions is proposed. Keywords Al2O3 · Alumina · Laser · Assisted · Micro · Grinding
1 Introduction Ceramics are very important materials in many industries because of their superior mechanical and chemical properties. Alumina ( Al2O3) is a ceramic that has been used in microfluidics and biomedical implant production [1–4]. However, it is difficult to machine because of its high hardness and strength. Conventional machining methods cannot be used because of the low machining speed and high tool wear, and nonconventional methods are unsuitable because of their chemical stability. To overcome the machining problems, several studies have investigated nonconventional and hybrid machining methods. Electrochemical discharge machining (ECDM), a * Ki Young Song [email protected] 1
Mobile Communications Company, LG Electronics, 10, Magokjungang 10‑ro, Gangseo‑gu, Seoul 07796, South Korea
2
Seoul National University, 1, Kwanak‑ro, Kwanak‑gu, Seoul 08826, South Korea
3
Soongsil University, 369, Sangdo‑ro, Dongjak‑gu, Seoul 06978, South Korea
nonconventional method, can be used to fabricate microgrooves on Al 2O3 [5]; however, the process has a low material removal rate (MRR). Recently developed hybrid processes offer several strategies to compensate for the deficiencies of traditional machining methods [6, 7]. Previous studies have focused on the effects of hybrid machining on hard-to-cut materials; however, the effects on the microchannel fabrication of A l2O3
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