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Research Papers

Grinding Characteristics, Material Removal, and Damage Formation Mechanisms of Zirconia Ceramics in Hybrid Laser/Grinding

[+] Author and Article Information
Sheng Xu

State Key Laboratory of Mechanical System
and Vibration,
Shanghai 200240, China;
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Minhang District,
Shanghai 200240, China

Zhenqiang Yao

State Key Laboratory of Mechanical System
and Vibration,
Shanghai 200240, China;
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Minhang District,
Shanghai 200240, China
e-mail: zqyao@sjtu.edu.cn

Jiawei He

School of Mechanical Engineering,
Shanghai Jiao Tong University,
Minhang District,
Shanghai 200240, China

Jian Xu

Department of International Defense System,
Nanjing Research Institute of
Electronic Engineering,
Nanjing 210000, China

1Corresponding author.

Manuscript received March 31, 2017; final manuscript received March 4, 2018; published online May 11, 2018. Assoc. Editor: Kai Cheng.

J. Manuf. Sci. Eng 140(7), 071010 (May 11, 2018) (9 pages) Paper No: MANU-17-1199; doi: 10.1115/1.4039645 History: Received March 31, 2017; Revised March 04, 2018

Zirconia ceramics which are sometimes called “ceramic steel” have gained significant interest because of their excellent properties. However, it is desired to maintain the surface quality while increasing the economics of ceramics grinding process. A hybrid laser/grinding (HLG) process was utilized to grind zirconia ceramics which was irradiated with continuous wave laser before grinding in the hybrid process. The feasibility of hybrid laser/grinding of zirconia ceramics was investigated in terms of grinding force and energy, material removal, and damage formation mechanisms. The results show that laser irradiation can induce lateral cracks, which can help material removal and prevent further crack propagating into the base. The results of grinding tests indicate that grinding force and energy decrease significantly as compared with conventional grinding of ceramics. The combinations of the fractured area, the plowing striations, and seldom debris on the ground surfaces in this work indicate the combined material removal mechanism of both brittle mode and ductile mode.

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Figures

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Fig. 1

Schematic of irradiation experimental setup

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Fig. 2

Illustration of the grinding experimental setup

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Fig. 3

Optical micrographs of zirconia surface before laser irradiation (a) and after laser irradiation (b) from the top view

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Fig. 4

Optical micrographs of subsurface cracks induced by laser irradiation (a) and the schematic of subsurface cracks (b) from the cross section view

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Fig. 5

Three-dimensional images of the ground terraced structure (vs = 30 m/s, vw = 8 m/min, ap = 15 μm)

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Fig. 6

Optical micrographs of the ground surfaces (vs = 30 m/s, vw = 8 m/min, ap = 15 μm)

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Fig. 7

Optical micrographs of the subsurface cracks (vs = 30 m/s, vw = 8 m/min, ap = 15 μm)

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Fig. 8

Optical micrographs of the ground surfaces (vs = 30 m/s, vw = 0.6 m/min) with: (a) ap = 10 μm, (b) ap = 20 μm, (c) ap = 30 μm, (d) ap = 40 μm, and (e) ap = 50 μm

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Fig. 9

Optical micrographs of the subsurface cracks (vs = 30 m/s, vw = 0.6 m/min) with (a) ap = 10 μm, (b) ap = 20 μm, (c)ap = 30 μm, (d) ap = 40 μm, and (e) ap = 50 μm

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Fig. 10

Normal grinding force versus the depth of removal (vs = 30 m/s, vw = 0.6 m/min)

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Fig. 11

Relative decreasing ratio of normal grinding force versus the depth of removal (vs = 30 m/s, vw = 0.6 m/min)

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Fig. 12

Specific grinding energy versus depth from the original surface (vs = 30 m/s, vw = 0.6 m/min)

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Fig. 13

Normalized specific grinding energy versus depth of removal

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Fig. 14

Illustration of grinding the specimen with laser irradiated cracks

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Fig. 15

The relationship of grinding power versus the plowed surface area

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