Abstract
To study the effect of material properties on the surface morphology of potassium dihydrogen phosphate (KDP) crystals, an ultra-precision fly cutting machine tool with a single-point diamond tool was used to perform a cutting experiment on (100) crystal plane of the KDP crystal. The elastic modulus, shear modulus, hardness, and dislocation of KDP crystals are taken into the cutting force model by introducing the strain gradient plasticity theory. Since the size effect and dynamic response will affect the surface roughness during ultra-precision machining, the surface roughness of workpieces in ultra-precision fly cutting is hard to predict. Based on the previously established strain gradient plasticity theoretical model, cutting force model, and the dynamic characteristics of the ultra-precision fly cutting system, a surface morphology prediction model under the influence of KDP crystal material properties was established. Finally, the accuracy of the surface morphology prediction model was verified by ultra-precision fly cutting experiments, and identified the frequency range of the characteristic signal caused by the anisotropy of the KDP crystal from the frequency, thereby verifying the KDP crystal material properties has a significant effect on the surface of the machined workpiece roughness.
Highlights
As an electro-optic crystal material, potassium dihydrogen phosphate (KDP) crystals is widely used in frequency multipliers, three-dimensional optical data storage devices and a new generation of 100 Joule laser systems due to its better nonlinear optical properties [1]
Most of these studies focus on the analysis of experimental results, and there are few theoretical studies on the effect of Keywords: potassium dihydrogen phosphate (KDP) crystal material properties on surface morphology
During the process of ultra-precision fly cutting of KDP crystals, the mechanical properties of KDP crystal materials will cause the fluctuation of cutting force, which will eventually cause the surface quality of KDP crystals to change
Summary
As an electro-optic crystal material, potassium dihydrogen phosphate (KDP) crystals is widely used in frequency multipliers, three-dimensional optical data storage devices and a new generation of 100 Joule laser systems due to its better nonlinear optical properties [1]. In ultra-precision machining, due to the small processing scale the effect of workpiece material properties on surface morphology cannot be ignored [5]. The results show that the formation of deformation band is direction dependent Most of these studies focus on the analysis of experimental results, and there are few theoretical studies on the effect of KDP crystal material properties on surface morphology. Luo et al [32] analyzed the ultra-precision turning surface by 2D power spectral density method, and found that the local shear stress significantly affected the machined surface morphology, and the feed rate, tool wear and regeneration effect vibration had some influence. It is of great significance to explore the effect of the material properties of KDP crystals on ultra-precision fly cutting process to improve surface quality. The frequency range of the characteristic signal caused by the anisotropy of the KDP crystal can be identified from the results
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