Investigation on machining performance of soft-brittle KDP crystals with surface micro-defects in the ball-end milling repairing process

Hongqin Lei, Linjie Zhao, Jian Cheng, Mingjun Chen, Qi Liu, Jinghe Wang, Dinghuai Yang, Wenyu Ding, Guang Chen, Chengshun Han

Research output: Contribution to journalArticlepeer-review

2 Citations (SciVal)

Abstract

Micro ball-end milling technology is an excellent repair strategy for economically removing surface micro-defects of large-scale KDP optics in the high-power laser devices. However, it is an urgent challenge for defective KDP crystals to achieve ultra-smooth repaired surface in ductile mode cutting, because pre-existing surface defects with different geometry and dimensions can affect machining performance during the reparative process by changing the uncut chip thickness (UCT). Therefore, the influence of various surface micro-defects on the machining performance is systematically investigated from the perspectives of the UCT, tensile stress, cutting force, and surface quality in this work. Interestingly, the plastic scratches and fracture pits could transform the brittle mode cutting into a ductile removal process by increasing the UCT, showing a decrease in the brittle fractures, the maximum tensile stress and the fluctuation of cutting force, indicating that the ductile removal ability can be improved. While, the effect of the surface protuberances on the repair quality is opposite. Besides, although the convex scratches and the cracks could cause a slight increase in the UCT, it has almost no impact effect on the material removal mode. More interestingly, for the fracture pits with specific dimensions, when it is not completely removed, the growth behavior of defect dimensions occurs during the reparative process due to the action of mechanical forces, reducing the surface quality. Consequently, the above work provides significant theoretical importance and engineering application value to formulate corresponding repair strategies for various surface defects to obtain the ultra-smooth surface of optical components.

Original languageEnglish
Article numbere00884
JournalSustainable Materials and Technologies
Volume40
Early online date7 Mar 2024
DOIs
Publication statusPublished - 1 Jul 2024

Data Availability Statement

Data will be made available on request.

Funding

This study was financially supported under the National Natural Science Foundation of China (Nos. 52175389, 52235010, 52293403), the Natural Science Foundation of Heilongjiang Province (No. YQ2021E021), the Young Elite Scientists Sponsorship Program by CAST (No. 2018QNRC001), the Fundamental Research Funds for the Central Universities (No. 5710052222) and the Self-Planned Task Foundation of State Key Laboratory of Robotics and System (HIT) of China (Nos. SKLRS201718A, SKLRS201803B).

FundersFunder number
National Natural Science Foundation of China52175389, 52235010, 52293403
Natural Science Foundation of Heilongjiang ProvinceYQ2021E021
China Academy of Space Technology2018QNRC001
Fundamental Research Funds for the Central Universities5710052222, SKLRS201718A, SKLRS201803B

    Keywords

    • Ball-end milling
    • KDP crystal
    • Machining performance
    • Surface micro-defect

    ASJC Scopus subject areas

    • Renewable Energy, Sustainability and the Environment
    • General Materials Science
    • Waste Management and Disposal
    • Industrial and Manufacturing Engineering

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