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<p>This study investigates the predictive modeling of zinc sulfide (ZnS) materials subjected to hot isostatic pressing, aimed at enhancing ultraprecision turning processes for brittle polycrystalline materials while preventing breakage. Ultraprecision cutting requires ductile-mode machining to mitigate surface defects commonly associated with brittle materials. This innovative approach eliminates the need for polishing during the machining process. This study focused specifically on polycrystalline ZnS, utilizing diamond turning techniques to elucidate the fundamental mechanisms involved in machining brittle materials, particularly those with polycrystalline configurations. The key factors influencing these mechanisms were identified, including the properties of the workpiece material, the characteristics of the cutting tool, and the conditions under which machining occurs. A predictive model was developed to estimate the fluctuations in the critical uncut chip thickness during ductile-to-brittle transition. A novel aspect of this model is its capacity to incorporate anisotropic material behavior across various crystal planes and cutting directions, thus providing more precise predictions of material responses under diverse machining conditions. This distinctive feature considerably improves the reliability of ductile-mode machining strategies compared to traditional models that predominantly examine single-crystal materials. Both theoretical and experimental approaches were employed to validate the precision of the model, with turning and grooving experiments conducted on polycrystalline ZnS materials. The results revealed that the polycrystalline ZnS demonstrates a surface roughness of 0.9&#xa0;nm when the maximum chip thickness remains below 40&#xa0;nm, confirming the viability of ductile cutting across all crystal planes. The proposed model provided a method for machining brittle materials in a ductile manner without relying on experimental techniques. The transition of research focus from single-crystal to polycrystalline materials has validated the applicability of predictive modeling to brittle polycrystalline substances.</p>

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Effect of Crystal Structure on Material Behavior in Ultraprecision Diamond Turning of Polycrystalline Zinc Sulfide

  • 期刊论文

  • 发表日期：

    2025年7月31日

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  • Woo-Jong Yeo,
  • Hwan-Jin Choi,
  • Minwoo Jeon,
  • I Jong Kim,
  • Mincheol Kim,
  • Geon-Hee Kim,
  • Wonkyun Lee

摘要

This study investigates the predictive modeling of zinc sulfide (ZnS) materials subjected to hot isostatic pressing, aimed at enhancing ultraprecision turning processes for brittle polycrystalline materials while preventing breakage. Ultraprecision cutting requires ductile-mode machining to mitigate surface defects commonly associated with brittle materials. This innovative approach eliminates the need for polishing during the machining process. This study focused specifically on polycrystalline ZnS, utilizing diamond turning techniques to elucidate the fundamental mechanisms involved in machining brittle materials, particularly those with polycrystalline configurations. The key factors influencing these mechanisms were identified, including the properties of the workpiece material, the characteristics of the cutting tool, and the conditions under which machining occurs. A predictive model was developed to estimate the fluctuations in the critical uncut chip thickness during ductile-to-brittle transition. A novel aspect of this model is its capacity to incorporate anisotropic material behavior across various crystal planes and cutting directions, thus providing more precise predictions of material responses under diverse machining conditions. This distinctive feature considerably improves the reliability of ductile-mode machining strategies compared to traditional models that predominantly examine single-crystal materials. Both theoretical and experimental approaches were employed to validate the precision of the model, with turning and grooving experiments conducted on polycrystalline ZnS materials. The results revealed that the polycrystalline ZnS demonstrates a surface roughness of 0.9 nm when the maximum chip thickness remains below 40 nm, confirming the viability of ductile cutting across all crystal planes. The proposed model provided a method for machining brittle materials in a ductile manner without relying on experimental techniques. The transition of research focus from single-crystal to polycrystalline materials has validated the applicability of predictive modeling to brittle polycrystalline substances.