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蓝宝石单晶ELID磨削表面质量研究
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摘要
本论文利用了ELID(Electrolytic In-Process Dressing,ELID)方法,对蓝宝石进行塑性磨削研究,同时对青龙玉,微晶玻璃等不同硬度材料进行ELID磨削研究。实验采用了GM73-Ⅲ型超精密平面磨床,铸铁基短纤维结合剂金刚石砂轮(粒度为W5),配合在线电解修整,通过调整砂轮单位进给量和砂轮转速,实现了对蓝宝石的塑性切削;并通过对青龙玉,微晶玻璃等性材料的ELID磨削,研究了单位进给量和砂轮转速对表面粗糙度的影响。利用表面光度仪(XP-2TM)、原子力显微镜(Atomic Force Microscope,AFM)和偏光显微镜(DMRXP)分别对蓝宝石加工表面轮廓、表面形貌和表面加工缺陷进行了分析。并采用X射线衍射小角度掠入射的方法,对蓝宝石加工表面变质层进行了研究。
     研究结果表明,本实验中,用ELID方法对蓝宝石进行磨削,表面粗糙度值随单位进给量增大而增大,随砂轮转速增大呈先降低后升高的趋势;蓝宝石磨削有性断裂和塑性切削两种模式;当单位进给量为1μm,砂轮转速为1900 rpm时,蓝宝石处于塑性域磨削,得到表面粗糙度值为3.2 nm。利用ELID方法,与传统磨削抛光相比,大大减少了蓝宝石材料表面的加工缺陷,实现了以磨代抛,提高了加工效率,蓝宝石加工表面变质层厚度仅为2.33μm,满足了蓝宝石基片作为功能材料的精度要求和光学要求。本实验用ELID方法磨削不同硬度的性材料,均满足表面粗糙度随砂轮转速增加而先降低后增大的趋势,且最低表面粗糙度对应的砂轮转速随材料硬度增大而降低。
The surface of sapphire crystal grinded under ductile mode was discussed with the Electrolytic In-Process Dressing(ELID) method in this paper. Different hardness materials, such as jade and glass ceramic, were also researched under ELID grinding. In this experiment, the ductile cutting mode of sapphire crystal has been achieved via changing the feed rate and the rotation speed of grinding wheel. All the sapphire crystal were grinded by ELID method on surface grinder that type is GM73-Ⅲand short cast iron fibers bonded diamond grinding wheel. Via grinding jade and glass ceramic with ELID method, the effect of feed rate and rotation speed to surface roughness had been researched. The surface profile, surface topography and manufacturing deficiency had been researched separately by using profilometer (XP-2TM), Atomic Force Microscope (AFM) and polarization microscope (DMRXP). Then the metamorphic layer was studied by grazing incidence X-ray diffraction method.
     The result showed that the surface roughness of sapphire crystal grinded by ELID method increases with the feed rate increasing, and the surface roughness decreases at first and then increaseswith the rotation speed increasing. There are two mode when the sapphire crystal was grinded, such as brittle fracture and ductile cutting. When the feed rate was 1μm and the rotation speed was 1900 rpm, the sapphire crystal was grinded under ductile cutting, the surface roughness of sapphire crystal was 3.2 nm. The manufacturing deficiency of sapphire crystal grinded by ELID method was reduced greatly compare to the surface grinded by traditional grinding method and polishing. The traditional grinding method and polishing was replaced by ELID method, and the efficiency also was improved. The thickness of metamorphic layer of sapphire crystal grinded by ELID is 2.33μm, which satisfied the request of sapphire crystal slice as functional material. After grinding the different hardness materials by ELID method, the direction that the surface roughness decreases at first and then increases when the rotation speed increases had been proved. And the corresponding rotation speed of the lowest surface roughness decreases withthe hardness increasing.
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