Infrared and Laser Engineering, Volume. 54, Issue 3, 20240613(2025)
Research on freeform surface machining of glass-ceramic based on laser-assisted cutting technology (invited)
Mingxu FAN1... Jianke ZHAO1, Wei HAO1, Jiaoteng DING1, Xiabin JI1, and Guoyan SUN12,*
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Author Affiliations
1Xi’an Institute of Optics and Precision Mechanics, Chinese Academy of Sciences, Xi’an 710119, China2National University of Defense Technology, Changsha 410003, Chinashow less
ObjectiveGlass-ceramic is a kind of optical hard and brittle material with broad application prospects in aerospace, medical treatment, electronics and other fields. Glass-ceramic is required to process the free-form surface on the surface in many application scenes. However, due to the high hardness and brittleness of the glass-ceramic itself, the processing difficulty is greatly improved. Therefore, it is necessary to develop a precision or ultra-precision processing method that can effectively improve the processing quality and efficiency of the free-form surface of glass-ceramic.
MethodsIn this paper, laser assisted machining (LAM) and fast tool servo (FTS) technologies are combined to design a laser-assisted fast tool servo cutting device which can be used to cut the free-form surface shape of glass-ceramic, and the structure and working mode of the device are described. The elastic beam method is used to calculate the displacement amplification ratio of the diamond amplification mechanism in the flexure hinge mechanism. The deviation and displacement amplification ratio of the output displacement of the two levers displacement amplification mechanism in the flexure hinge mechanism are obtained through the static simulation. The equivalent stress of the flexure hinge mechanism is analyzed. The static laser irradiation temperature measurement experiment of glass-ceramic is carried out to obtain the maximum laser power threshold that can be withstood by the actually processed glass-ceramic. The laser assisted fast tool servo cutting experiment is carried out to obtain the free-form surface topography of glass-ceramic. The surface roughness after conventional FTS cutting and laser assisted cutting is compared and analyzed, and the influence of process parameters on the surface roughness is also analyzed.
Results and DiscussionsThe theoretical displacement amplification ratio of the diamond amplification mechanism calculated by the elastic beam method is 2.83. The absolute error of the output displacement of the two levers displacement amplification output end of the flexible hinge mechanism is 0.17 μm through the static simulation, and the two can output synchronous displacement. The displacement amplification ratio is 6.35. The equivalent stress analysis results show that the maximum stress of the flexible hinge mechanism is less than the allowable stress of the material. The theoretical calculation and static simulation verify that the flexible hinge mechanism has good displacement amplification and output characteristics, and the mechanism is safe and reliable. The static laser irradiation temperature measurement experiment of glass-ceramic has determined that the maximum acceptable laser power in actual processing is 75 W. The free-form surface topography is obtained in the laser-assisted fast cutting experiment of glass-ceramic. The surface roughness decreases with the increase of laser power and the decrease of spindle speed. The maximum surface roughness reduction was 58.2% when laser power was 75 W.
ConclusionsThe research shows that the laser assisted fast tool servo cutting method can improve the surface processing quality greatly compared with the conventional FTS cutting method when successfully cutting the free surface morphology of glass-ceramic.