Studying a grinding method of sapphire pipes using two grinders

This paper examines the thermophysics of a drilling process of polymeric composite materials such as carbonfibre-reinforced plastics (CFRP) and fibreglass by tubular diamond drill bits. Features of the COMSOL Multiphysics engineering software package were used. We employed Fourier heat equations, which express the intensity of heat gain by a mobile source in a moving coordinate system. The research was performed using the proprietary method of modelling spatial thermal action upon drilling polymer composite materials (fibreglass and carbon-fibre-reinforced plastics) in the COMSOL Multiphysics software environment. A tubular diamond drill bit with a diameter of 10 mm with two slots was chosen as a model cutting tool. Solid plates with a thickness of 5.5 mm made of layered fibrous polymer composite materials (fibreglass, carbon-fibre-reinforced plastic) were used as a preform. As a result of computer calculations, we obtained temperature fields of fibreglass and carbon-fibre-reinforced plastic during diamond drilling with the tubular tool. When studying the thermal behaviour of fibreglass and carbon-fibre-reinforced plastics, maximum temperature fields were located. The study revealed that the temperature reaches 413.6 K and 448.7 K during CFRP and fibreglass drilling, respectively. It was shown that the distance of heat transfer from the edge of the hole into the preform was 6.42 and 6.40 mm for CFRP and fibreglass, respectively. A method of modelling the thermal effects when cutting polymer composite materials developed in the COMSOL Multiphysics environment allows complex analytical calculations of temperatures induced by drilling to be simplified. In addition, it helps avoid overheating of a preform during drilling, allows the depth of heat distribution inside the preform from the edge of the formed hole in different polymer composite materials to be assessed. These measures lead to increasing the machining quality of polymer composite materials.

1. Teplova TB, Samerhanova AS. Development trend of using high-strength solid materials in microelectronics, medicine and jewelry. Gornyj informacionno-analiticheskij byulleten' = Mining informational and analytical bulletin. 2006;10:339–347. (In Russ.)

2. Kurlov VN, Rassolenko SN. Controlling sapphire crystal shape and quality when growing by the method of noncapillary shaping. Vyrashchivanie kristallicheskih izdelij sposobom Stepanova, plastichnost' i prochnost' kristallov: tezisy dokladov Vserossijskogo soveshchaniya = Growing crystalline products by Stepanov’s method, crystal plasticity and strength: abstracts of the reports of All-Russian Meeting 22–24 October 2003, Saint-Petersburg. SaintPetersburg: Publishing House of the Ioffe Institute SB RAS; 2003, р. 6. (In Russ.)

3. Gavrish SV, Loginov VV, Puchnina SV. Pulsed gasdischarge IR radiation sources for optical-electronic systems (a review). Uspekhi Prikladnoi Fiziki = Advances in Applied Physics. 2018;6(4):333–348. (In Russ.)

4. Gavrish SV, Gaidukov EN, Konstantinov BA. Discharge sources of infrared radiation for special purposes. Svetotehnika = Light & Engineering. 1998;3:2224–2225. (In Russ.)

5. Gavrish SV. Discharge sources of radiation with a sapphire shell. Prikladnaya fizika = Applied Physics. 2011;4:42–51. (In Russ.)

6. Gavrish SV. Heat sink conditions influence on pulsed discharge IR radiation source parameters. Prikladnaya fizika = Applied Physics. 2018;5:86–93. (In Russ.)

7. Korolev AV. Selection of the optimal geometric shape of the contacting surfaces of machine parts and devices. Saratov: Saratov University Publ.; 1972, 134 p. (In Russ.)

8. Bochkin OI, Brook VA, Nikiforova-Denisova SN. Mechanical treatment of semiconductors. Moscow: Vysshaya shkola; 1983, 112 p. (In Russ.)

9. Korsakov BC. Machining Precision. Moscow: Mashgiz; 1961, 379 p. (In Russ.)

10. Korchak SN. Productivity of steel parts grinding. Moscow: Mashinostroenie; 1974, 280 p. (In Russ.)

11. Lurie GB. Progressive methods of external cylindrical grinding. Leningrad: Mashinostroenie; 1984, 103 p. (In Russ.)

12. Grabchenko AI, Fedorovich VA, Shahbazov YaA, Rusanov VV. Ways to improve machining efficiency when treating with abrasive grinding wheels. In: Rezanie i instrument v tekhnologicheskih sistemah: Mezhdunar. nauchno-tekhnicheskij sbornik = Cutting and tools in technological systems: International scientific and technical collection of articles. 74. Har'kov: National Technical University “Kharkiv Polytechnic Institute; 2008, р. 70–83.

13. Matsui S, Tamaki I. Influence of the elastic displacement of grain cutting edges on grinding mechanism. Technology Reports of the Tohoku University. 1976;41(1):73–88.

14. Savitsky IV, Voytenko VA. Increasing the accuracy of sapphire tube processing by reducing mechanical stress. Resursosberegayushchie tekhnologii proizvodstva i obrabotki davleniem materialov v mashinostroenii. 2020;3:61–68. (In Russ.)

15. Kudinov VA, Todorov NT. Development regularities of vibration and wheel and product waviness under plungecut grinding. Stanki i instrument. 1970;2:1–3. (In Russ.)

16. Kudinov VA, Grishin VM. Dynamic frequency characteristics of grinding. Stanki i instrument. 1972;1:7–9. (In Russ.)

17. Savitskiy IV, Voitenko VA. A new grinding method of cylindrical surfaces. Problemy i perspektivy mezhdunarodnogo transfera innovacionnyh tekhnologij: sbornik statej po itogam Mezhdunarodnoj nauchno-prakticheskoj konferencii = Problems and prospects of the international transfer of innovative technologies: collected articles based on the results of the International scientific and practical conference. 24 August 2020, Voronezh. Sterlitamak: International Research Agency Publ.; 2020, р. 56–59. (In Russ.)

18. Demkin NB. The actual contact area of solid surfaces. Moscow: USSR Academy of Sciences Publ.; 1962, 112 p. (In Russ.)

19. Klunnikova YuV. Research of abrasive treatment influence on process of defects formation in sapphire crystals. Inzhenernyj vestnik Dona. 2016;2:2. (In Russ.)

20. Evans AG, Wilshau TR. Quasi-static solid particle damage in brittle solids: observations, analysis and implications. Acta Metallurgica. 1976;24(10):936–956.

21. Kirchner HP, Ragosta JA. Relation of load to radial crack length for spherical indentations in hot‐pressed ZnS. Journal of the American Ceramic Society. 1983;66(4):293–296. https://doi.org/10.1111/j.1151-2916.1983.tb15717.x