Scholarlink

<p>Machining brittle materials such as K9 optical glass is particularly challenging due to their high hardness and susceptibility to fracture. This study introduces a novel electrochemical-assisted drilling (EAD) technique and compares its performance with conventional drilling (CD). In EAD, the drilling tool acts as a cathode, producing bubbles that enhance coolant flow, facilitate chip removal, and lower machining temperatures. Numerical simulations reveal that bubble-induced fluid dynamics improve heat dissipation and stabilize the machining process. Experiments demonstrate that EAD significantly reduces tool wear, brittle fractures, and subsurface damage, yielding superior surface quality, particularly at higher feed rates. Meanwhile, alkaline electrolytes (e.g., NaOH) outperform neutral solutions (e.g., NaCl) by enhancing chemical etching, resulting in smoother surfaces and reduced mechanical damage due to their chemical etching properties. Furthermore, EAD demonstrates the superior achievable drilling depth over CD, successfully producing micro holes with aspect ratios exceeding 15:1. The developed EAD technique significantly reduces tool wear while enhancing machining quality, exhibiting substantial potential for high-aspect-ratio micromachining applications. This study highlights the potential of EAD as a cost-effective and sustainable solution for high-aspect-ratio micro hole machining of brittle materials, demonstrating prolonged tool longevity, enhanced surface integrity, and improved process stability.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

A novel electrochemical-assisted method for high-precision machining of optical glass

  • 期刊论文

  • 发表日期：

    2025年8月26日

查看全文
  • Tianhao Cheng,
  • Wei Han,
  • Lingbao Kong

摘要

Machining brittle materials such as K9 optical glass is particularly challenging due to their high hardness and susceptibility to fracture. This study introduces a novel electrochemical-assisted drilling (EAD) technique and compares its performance with conventional drilling (CD). In EAD, the drilling tool acts as a cathode, producing bubbles that enhance coolant flow, facilitate chip removal, and lower machining temperatures. Numerical simulations reveal that bubble-induced fluid dynamics improve heat dissipation and stabilize the machining process. Experiments demonstrate that EAD significantly reduces tool wear, brittle fractures, and subsurface damage, yielding superior surface quality, particularly at higher feed rates. Meanwhile, alkaline electrolytes (e.g., NaOH) outperform neutral solutions (e.g., NaCl) by enhancing chemical etching, resulting in smoother surfaces and reduced mechanical damage due to their chemical etching properties. Furthermore, EAD demonstrates the superior achievable drilling depth over CD, successfully producing micro holes with aspect ratios exceeding 15:1. The developed EAD technique significantly reduces tool wear while enhancing machining quality, exhibiting substantial potential for high-aspect-ratio micromachining applications. This study highlights the potential of EAD as a cost-effective and sustainable solution for high-aspect-ratio micro hole machining of brittle materials, demonstrating prolonged tool longevity, enhanced surface integrity, and improved process stability.