Modelling and experimental study on brittle-to-ductile transition during ultrasonic elliptical vibration-assisted cutting of zirconia ceramics

Abstract

Zirconia ceramics are often used in electronics, aerospace, biomedicine, and other fields because of their excellent mechanical and optical properties; however, as they are hard and brittle materials, they are highly susceptible to cracking and chipping during processing. Ultrasonic elliptical vibratory-assisted cutting (UEVC) is a promising ceramic processing technology that addresses existing problems in materials processing. In this study, the critical depth of cut (

h_{\text{c}}

\documentclass[12pt]{minimal}\usepackage{amsmath}\usepackage{wasysym}\usepackage{amsfonts}\usepackage{amssymb}\usepackage{amsbsy}\usepackage{mathrsfs}\usepackage{upgreek}\setlength{\oddsidemargin}{-69pt}\begin{document}$$h_{{\text{c}}}$$\end{document}

) of zirconia ceramics was predicted using two models, focusing on the influence of the circular edge of the tool and tool front angle in the actual machining process. Subsequently, a model was established based on the specific cutting energy to predict the

h_{\text{c}}

\documentclass[12pt]{minimal}\usepackage{amsmath}\usepackage{wasysym}\usepackage{amsfonts}\usepackage{amssymb}\usepackage{amsbsy}\usepackage{mathrsfs}\usepackage{upgreek}\setlength{\oddsidemargin}{-69pt}\begin{document}$$h_{{\text{c}}}$$\end{document}

of zirconia ceramics in UEVC machining. A simulation software was used to simulate the variable depth of zirconia ceramics using the constitutive improved Johnson-Holmquist ceramic (JH-2) model. Finally, the relationship between the cutting speed and

h_{\text{c}}

\documentclass[12pt]{minimal}\usepackage{amsmath}\usepackage{wasysym}\usepackage{amsfonts}\usepackage{amssymb}\usepackage{amsbsy}\usepackage{mathrsfs}\usepackage{upgreek}\setlength{\oddsidemargin}{-69pt}\begin{document}$$h_{{\text{c}}}$$\end{document}

of zirconia ceramics under conventional cutting (CC) and UEVC machining was investigated using scribing experiments. The results showed that the

h_{\text{c}}

\documentclass[12pt]{minimal}\usepackage{amsmath}\usepackage{wasysym}\usepackage{amsfonts}\usepackage{amssymb}\usepackage{amsbsy}\usepackage{mathrsfs}\usepackage{upgreek}\setlength{\oddsidemargin}{-69pt}\begin{document}$$h_{{\text{c}}}$$\end{document}

of zirconia ceramics decreased nonlinearly with increasing cutting speed. The

h_{\text{c}}

\documentclass[12pt]{minimal}\usepackage{amsmath}\usepackage{wasysym}\usepackage{amsfonts}\usepackage{amssymb}\usepackage{amsbsy}\usepackage{mathrsfs}\usepackage{upgreek}\setlength{\oddsidemargin}{-69pt}\begin{document}$$h_{{\text{c}}}$$\end{document}

of zirconia under CC is 0.8 μm, whereas the

h_{\text{c}}

\documentclass[12pt]{minimal}\usepackage{amsmath}\usepackage{wasysym}\usepackage{amsfonts}\usepackage{amssymb}\usepackage{amsbsy}\usepackage{mathrsfs}\usepackage{upgreek}\setlength{\oddsidemargin}{-69pt}\begin{document}$$h_{{\text{c}}}$$\end{document}

values of zirconia under UEVC machining are 1.79, 1.75, 1.45, and 1.3 μm with a maximum increment of 124%, which corroborates the results predicted by the model, verifying the effectiveness of the model and simulation.

Keywords

Ultrasonic elliptical vibration-assisted cutting (UEVC) / Zirconia ceramic / Brittle-to-ductile transition (BDT) / Specific cutting energy / Finite element simulation / Scribing experiment

References

[1] MaZ, WangQ, ChenH, et al.. Surface prediction in laser-assisted grinding process considering temperature-dependent mechanical properties of zirconia ceramic. J Manuf Process, 2022, 80: 491-503

[2] ShelarP, ButlerS, AbdolvandH, et al.. On the behaviour of zirconia-based dental materials: a review. J Mech Behav Biomed Mater, 2021, 124: 104861

[3] SavinoR, CriscuoloL, Di MartinoG, et al.. Aero-thermo-chemical characterization of ultra-high-temperature ceramics for aerospace applications. J Eur Ceram Soc, 2018, 38(8): 2937-2953

[4] BabbarA, JainV, GuptaD, et al.. Fabrication and machining methods of composites for aerospace applications. Characterization, testing, measurement, and metrology, 2020 Florida CRC Press 109-124

[5] BharathiV, AnilchandraAR, SangamSS, et al.. A review on the challenges in machining of ceramics. Mater Today Proc, 2021, 46: 1451-1458

[6] YangZ, ZhuL, LinB, et al.. The grinding force modeling and experimental study of ZrO₂ ceramic materials in ultrasonic vibration assisted grinding. Ceram Int, 2019, 45(7): 8873-8889

[7] BaraheniM, AminiS. Predicting subsurface damage in silicon nitride ceramics subjected to rotary ultrasonic assisted face grinding. Ceram Int, 2019, 45(8): 10086-10096

[8] ShamotoE, MoriwakiT. Study on elliptical vibration cutting. CIRP Ann, 1994, 43(1): 35-38

[9] BrehlDE, DowTA. Review of vibration-assisted machining. Precis Eng, 2008, 32(3): 153-172

[10] Suzuki N, Yan Z, Hino R et al (2006) Ultraprecision micro-machining of single crystal germanium by applying elliptical vibration cutting. In: Proceedings of the 2006 IEEE international symposium on micronano mechanical and human Science. IEEE, Nagoya

[11] YangZ, ZhuL, ZhangG, et al.. Review of ultrasonic vibration-assisted machining in advanced materials. Int J Mach Tool Manuf, 2020, 156: 103594

[12] KingRF, TaborD. The strength properties and frictional behaviour of brittle solids. Proc R Soc Lond A Math Phys Sci, 1954, 223(1153): 225-238

[13] SwainMV. Microfracture about scratches in brittle solids. Proc R Soc Lond A Math Phys Sci, 1979, 366(1727): 575-597

[14] BlakePN, ScattergoodRO. Ductile─regime machining of germanium and silicon. J Am Ceram Soc, 1990, 73(4): 949-957

[15] ZhangX, ArifM, LiuK, et al.. A model to predict the critical undeformed chip thickness in vibration-assisted machining of brittle materials. Int J Mach Tool Manuf, 2013, 69: 57-66

[16] ShamotoE, SuzukiN. Development of elliptical vibration cutting technology and its application to ultraprecision/micro machining of hard/brittle materials. Adv Mater Res, 2009, 69: 133-137

[17] ZhouM, WangXJ, NgoiBKA, et al.. Brittle–ductile transition in the diamond cutting of glasses with the aid of ultrasonic vibration. J Mater Process Technol, 2002, 121(2/3): 243-251

[18] LiangZ, WangX, WuY, et al.. Experimental study on brittle–ductile transition in elliptical ultrasonic assisted grinding (EUAG) of monocrystal sapphire using single diamond abrasive grain. Int J Mach Tool Manuf, 2013, 71: 41-51

[19] LiL, XuJ, JiM, et al.. On crack suppression mechanisms of ultrasonic elliptical vibration cutting of 3Y-TZP ceramics. Ceram Int, 2022, 48(19): 28308-28326

[20] ArifM, ZhangX, RahmanM, et al.. A predictive model of the critical undeformed chip thickness for ductile−brittle transition in nano-machining of brittle materials. Int J Mach Tool Manuf, 2013, 64: 114-122

[21] WangJ, GuoB, ZhaoQ, et al.. Evolution of material removal modes of sapphire under varied scratching depths. Ceram Int, 2017, 43(13): 10353-10360

[22] KurniawanR, KiswantoG, KoTJ. Micro-dimple pattern process and orthogonal cutting force analysis of elliptical vibration texturing. Int J Mach Tool Manuf, 2016, 106: 127-140

[23] Zhang X (2012) A study of elliptical vibration cutting in ultra precision machining. Dissertation, National University of Singapore

[24] Negishi N (2003) Elliptical vibration assisted machining with single crystal diamond tools. Dissertation, North Carolina State University

[25] BifanoTG, DowTA, ScattergoodRO. Ductile regime grinding: a new technology for machining brittle materials. ASME J Eng Ind May, 1991, 113(2): 184-189

[26] BridgemanPW, SimonI. Effects of very high-pressure on glass. J Appl Phys, 1953, 24: 405-413

[27] ArifM, XinquanZ, RahmanM, et al.. A predictive model of the critical undeformed chip thickness for ductile–brittle transition in nano-machining of brittle materials. Int J Mach Tools Manuf, 2013, 64: 114-122

[28] WuX, LiL, ZhaoM, et al.. Experimental investigation of specific cutting energy and surface quality based on negative effective rake angle in micro turning. Int J Adv Manuf Technol, 2016, 82: 1941-1947

[29] ShawMC, CooksonJO Metal cutting principles, 2005 New York Oxford University Press

[30] ZhangJ, HanL, ZhangJ, et al.. Brittle-to-ductile transition in elliptical vibration-assisted diamond cutting of reaction-bonded silicon carbide. J Manuf Process, 2019, 45: 670-681

[31] ArconaC, DowTA. An empirical tool force model for precision machining. J Manuf Sci Eng, 1998, 120(4): 700-707

[32] UedaK, SugitaT, HiragaH, et al.. A J-integral approach to material removal mechanisms in microcutting of ceramics. CIRP Ann, 1991, 40(1): 61-64

[33] YuT, TengJG, WongYL, et al.. Finite element modeling of confined concrete-I: Drucker-Prager type plasticity model. Eng Struct, 2010, 32(3): 665-679

[34] JohnsonGR, HolmquistTJ. An improved computational constitutive model for brittle materials. AIP Conf Proc, 1994, 309: 981-984

Funding

Key R&D projects of Jilin Provincial Department of Science and Technology(20240302037GX)

Natural Science Foundation of Jilin Province(YDZJ202301ZYTS258)

Jilin Provincial International Cooperation Key Laboratory for High-Performance Manufacturing and Testing(20220502003GH)

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature