Abstract
Freeform surfaces including both the aspherical and prismatic concave/convex have been widely utilized in optical, electronical, and biomedical areas. Most recently, it is reported that grinding with structured wheels provides new possibility to generate patterns on hard and brittle materials. This paper reports the latest research progress on micro-grooving glass ceramic using laser structured diamond grinding wheels. A nanosecond pulse laser is firstly integrated into an ultra-precision machine tool and used for the in-line conditioning of super abrasive grinding wheels, i.e., truing, dressing, and profiling/texturing. Meanwhile, an offset compensation method, considering the shifting depth of focus (DoF) at different laser irradiation positions, is proposed to accurately generate various profiles on the periphery of the grinding wheels. Three types of patterns (riblets, grooves, and pillars) are successfully fabricated on the ceramic substrate using the laser textured grinding wheels. The results indicate that the integrated laser system offers high flexibility and accuracy in shaping super abrasive grinding wheels, and the grinding using textured grinding wheels provides a promising solution to generate functional microstructures on hard and brittle materials.
Highlights
There are increasing applications of functional micro-/nanostructured surfaces in optical, electronical and biomedical areas
Several pioneering works have demonstrated the feasibility on micro-/nano-machining using facet, sharp point (S-point) and structured cutting tools to generate surface structures/ patterns [3]
The traditionally utilized mechanical conditioning tools such as diamond nibs, rollers, or dressing wheels are prone to serious wear after a period of working [8,9,10] because the mechanical conditioning process is a hard to hard contact with large force engaged between grinding wheels and conditioning tools
Summary
There are increasing applications of functional micro-/nanostructured surfaces in optical, electronical and biomedical areas. The achievable machining accuracy of surface structures significantly relies on the shape/profile of the structures generated on grinding wheels. The traditionally utilized mechanical conditioning tools such as diamond nibs, rollers, or dressing wheels are prone to serious wear after a period of working [8,9,10] because the mechanical conditioning process is a hard to hard contact with large force engaged between grinding wheels and conditioning tools. This will eventually result in form deviation of structures generated on tools. Research from Wang et al [19, 26] showed that the absorbed energy of grinding wheels changed significantly at different radial positions and incident angles, because the space distribution of absorbed and scattered energy was far more
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