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Advances in Manufacturing
Published in: Advances in Manufacturing 2/2019

06-06-2019

Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate

Authors: Tian-Feng Zhou, Ben-Shuai Ruan, Jia Zhou, Xiao-Bin Dong, Zhi-Qiang Liang, Xi-Bin Wang

Published in: Advances in Manufacturing | Issue 2/2019

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Abstract

Diamond cutting is a popular method to fabricate microlens array (MLA) on polymethyl methacrylate (PMMA); however, it is limited by brittle fracture, which is formed easily on the surface of MLA during the cutting process. In this paper, the formation mechanism of the brittle fracture is studied via a series of experiments including the slow tool servo (STS) cutting experiment of MLA, surface scratching experiment and sudden-stop cutting experiment. The effects of undeformed chip thickness, feed rate, and machining track on brittle fracture formation are investigated in detail. In addition, based on the fracture formation mechanism, a bi-directional cutting approach is proposed to eliminate the regional brittle fracture of the microlens during diamond cutting. An experiment was then conducted to verify the method; the results demonstrated that bi-directional cutting could eliminate brittle fracture entirely. Finally, a spherical MLA with the form error (vPV) of 60 nm and the surface roughness (Ra) of 8 nm was successfully fabricated.
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Metadata
Title
Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate
Authors
Tian-Feng Zhou
Ben-Shuai Ruan
Jia Zhou
Xiao-Bin Dong
Zhi-Qiang Liang
Xi-Bin Wang
Publication date
06-06-2019
Publisher
Shanghai University
Published in
Advances in Manufacturing / Issue 2/2019
Print ISSN: 2095-3127
Electronic ISSN: 2195-3597
DOI
https://doi.org/10.1007/s40436-019-00260-7

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