Optical surface quality and molecular dynamics modelling of ultra-high precision optical silicon machining
- Authors: Abdulkadir, Lukman Niyi
- Date: 2019-04
- Subjects: Lasers -- Industrial applications , Manufacturing processes , Materials science
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/66551 , vital:75600
- Description: Hard and brittle materials, such as silicon, silicon carbide etc., are widely used in aerospace, integrated circuit, and other fields due to their excellent physical and chemical properties. However, these materials display poor machinability owing to hardness, brittleness, non-linearity in machining process and complexities in selecting suitable machining parameters and tool geometry. These leads to low quality lenses due to subsurface damage and surface micro-crack. Additionally, it is experimentally very difficult to observe all nanoscale physical phenomena due to in-process measurement problems, inaccessible contact area of tool and workpiece, and the difficulty of surface analysis. With the use of molecular dynamics (MD) which is a comprehensive nanoscale modelling technique, proper selection of process parameters, tool geometry and online monitoring techniques, production of freeform optics is possible through Ultra-high precision diamond turning (UHPDT). Though, depending on view point, machinability in UHPDT may be in terms of tool wear rate, hardness, chip morphology, surface roughness, and other benchmarks. These situations have called for more insights, which on the long run will help to achieve high precision manufacturing with predictability, repeatability, productivity and high infrared (IR) optical quality. In this thesis, UHPDT of monocrystalline silicon at atomistic scale was conducted to investigate combined effects of edge radius, feed rate, cutting speed, depth of cut, rake and clearance angles hitherto not done so far. Using appropriate potential functions with the MD algorithm, comprehensive analysis of thermal effects, diamond tool wear, phase change, cutting forces and machining stresses (normal, shear, hydrostatic and von Mises) were carried out. Dislocation extraction algorithm (DXA) and radial distribution function (RDF) were used to evaluate dislocation nucleation, variations in bond lengths, microstructural transformation and represents structural changes in histogram form. Selected parameters for optical quality surface roughness were afterwards compared and optimized through response surface methodology (RSM) based on Box Behnken (BBD) and Taguchi L9 methods. The results indicated that, silicon atoms in the chip formation zone undergo high pressure phase transformation (HPPT) at high hydrostatic pressure and temperature Silicon microstructure transformed from four-coordinated diamond cubic structure (Si-I) to unstable six-coordinated body-centered tetragonal structure (β-silicon) which then transformed to amorphous silicon atoms (a-Si) through amorphization. These resulted in plastic deformation and defects in the machining zone causing subsurface damage. Stress analysis indicated that the compressive stress in the machining zone (i.e.amorphous region) suppressed crack formation contributing to continuous plastic flow which is responsible for silicon ductile-mode cutting. Furthermore, formation of silicon carbide which constituted diamond wear was observed to be by sp3 - sp2 diamond carbon atom disorder and tribochemistry. The tribochemistry occurred through both multiphase and solid-state single-phase reaction between diamond tool and silicon workpiece at cutting temperatures above and below 959 K. Both the experimental findings and the simulation results reveal that, at edge radius less than uncut chip thickness, tool wear was more of rake wear than flank wear. Tool wear and kinetic friction reduced as the edge radius approached the uncut chip thickness while forces, stresses and SCE increased. When machining silicon at different ratio, silicon stress state, SCE, SSD, forces (reduced with increase in clearance angle), shear plane, chip velocity and chip ratio increased as edge radius and rake angle increased, while, kinetic friction, chip length and thickness reduced. The crystal lattice of the machined surfaces and subsurface deformed layer depth increased with increase in edge radius, feed and rake angle. Amongst all tested and analysed parameters, feed rate had the highest influence on surface quality while depth of cut showed the least. Acoustic emission was also monitored during machining and its results statistically analysed. The trends of the monitored acoustic emissions showed its capability to adequately represent and predict surface roughness results. Based on the developed simulation model a novel method for quantitative assessment of tool wear was proposed. The proposed model can be used to compare tool wear using graphitization and tribochemistry to decide the path and mode of the diamond tool wear. Finally, based on the experiment results and predictive model, a novel combination and hierarchical arrangement of the considered factors capable of suppressing tool wear and improve attainable machined surface roughness when turning hard-to-machine materials was proposed. , Thesis (PhD) -- Faculty of Engineering, the Built Environment, and Technology, School of Engineering, 2019
- Full Text:
- Date Issued: 2019-04
- Authors: Abdulkadir, Lukman Niyi
- Date: 2019-04
- Subjects: Lasers -- Industrial applications , Manufacturing processes , Materials science
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/66551 , vital:75600
- Description: Hard and brittle materials, such as silicon, silicon carbide etc., are widely used in aerospace, integrated circuit, and other fields due to their excellent physical and chemical properties. However, these materials display poor machinability owing to hardness, brittleness, non-linearity in machining process and complexities in selecting suitable machining parameters and tool geometry. These leads to low quality lenses due to subsurface damage and surface micro-crack. Additionally, it is experimentally very difficult to observe all nanoscale physical phenomena due to in-process measurement problems, inaccessible contact area of tool and workpiece, and the difficulty of surface analysis. With the use of molecular dynamics (MD) which is a comprehensive nanoscale modelling technique, proper selection of process parameters, tool geometry and online monitoring techniques, production of freeform optics is possible through Ultra-high precision diamond turning (UHPDT). Though, depending on view point, machinability in UHPDT may be in terms of tool wear rate, hardness, chip morphology, surface roughness, and other benchmarks. These situations have called for more insights, which on the long run will help to achieve high precision manufacturing with predictability, repeatability, productivity and high infrared (IR) optical quality. In this thesis, UHPDT of monocrystalline silicon at atomistic scale was conducted to investigate combined effects of edge radius, feed rate, cutting speed, depth of cut, rake and clearance angles hitherto not done so far. Using appropriate potential functions with the MD algorithm, comprehensive analysis of thermal effects, diamond tool wear, phase change, cutting forces and machining stresses (normal, shear, hydrostatic and von Mises) were carried out. Dislocation extraction algorithm (DXA) and radial distribution function (RDF) were used to evaluate dislocation nucleation, variations in bond lengths, microstructural transformation and represents structural changes in histogram form. Selected parameters for optical quality surface roughness were afterwards compared and optimized through response surface methodology (RSM) based on Box Behnken (BBD) and Taguchi L9 methods. The results indicated that, silicon atoms in the chip formation zone undergo high pressure phase transformation (HPPT) at high hydrostatic pressure and temperature Silicon microstructure transformed from four-coordinated diamond cubic structure (Si-I) to unstable six-coordinated body-centered tetragonal structure (β-silicon) which then transformed to amorphous silicon atoms (a-Si) through amorphization. These resulted in plastic deformation and defects in the machining zone causing subsurface damage. Stress analysis indicated that the compressive stress in the machining zone (i.e.amorphous region) suppressed crack formation contributing to continuous plastic flow which is responsible for silicon ductile-mode cutting. Furthermore, formation of silicon carbide which constituted diamond wear was observed to be by sp3 - sp2 diamond carbon atom disorder and tribochemistry. The tribochemistry occurred through both multiphase and solid-state single-phase reaction between diamond tool and silicon workpiece at cutting temperatures above and below 959 K. Both the experimental findings and the simulation results reveal that, at edge radius less than uncut chip thickness, tool wear was more of rake wear than flank wear. Tool wear and kinetic friction reduced as the edge radius approached the uncut chip thickness while forces, stresses and SCE increased. When machining silicon at different ratio, silicon stress state, SCE, SSD, forces (reduced with increase in clearance angle), shear plane, chip velocity and chip ratio increased as edge radius and rake angle increased, while, kinetic friction, chip length and thickness reduced. The crystal lattice of the machined surfaces and subsurface deformed layer depth increased with increase in edge radius, feed and rake angle. Amongst all tested and analysed parameters, feed rate had the highest influence on surface quality while depth of cut showed the least. Acoustic emission was also monitored during machining and its results statistically analysed. The trends of the monitored acoustic emissions showed its capability to adequately represent and predict surface roughness results. Based on the developed simulation model a novel method for quantitative assessment of tool wear was proposed. The proposed model can be used to compare tool wear using graphitization and tribochemistry to decide the path and mode of the diamond tool wear. Finally, based on the experiment results and predictive model, a novel combination and hierarchical arrangement of the considered factors capable of suppressing tool wear and improve attainable machined surface roughness when turning hard-to-machine materials was proposed. , Thesis (PhD) -- Faculty of Engineering, the Built Environment, and Technology, School of Engineering, 2019
- Full Text:
- Date Issued: 2019-04
Influence of laser surface treatment on residual stress distribution and dynamic properties in rotary friction welded ti-6al-4v components
- Authors: Tsikayi, Davies Shamiso
- Date: 2019
- Subjects: Lasers -- Industrial applications , Friction welding Pressure welding Metals -- Research
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/43823 , vital:37050
- Description: This manuscript details a study on laser surface treatment, a surface modification technique that is an easily flexible way of improving material surface properties of complex geometries. The research explored the potential of laser surface modification/treatment as a post welding surface processing technique for RFW Ti-6Al-4V ELI components by evaluating the microstructural effects, influence on fatigue life and the depth and magnitude of residual stresses induced. The outcome of this study reveals how post processing by laser surface modification affects crack initiation hence fatigue life and further explains mechanisms potentially contributing to enhanced joint properties. This study was accomplished by investigating the effect of laser surface treatment on surface properties of hourglass cylindrical rotary friction welded Ti-6Al-4V ELI specimens. Preliminary work was done in two stages. The first stage involved conducting laser surface treatment on 3 mm Ti-6Al-4V sheets. In this stage, an understanding of the process variables concerning the laser surface treatment process characteristics was established. Laser power and focus position were varied whilst scanning speed was kept constant. The observed macrographs were quantified in terms of laser penetration depth and width. A hardness and microstructural analysis was also conducted on selected specimens of the laser surface treated flat sheets trials. The second stage involved surface treatment of the hourglass fatigue specimen. This preliminary work allowed for the type and influence of treatment strategy to be analysed. The influence of treatment strategy on the depth of penetration was established with an emphasis on achieving homogeneity of the laser surface treated zone’s depth of penetration around the complete cylindrical specimen’s diameter. The final matrix involved varying laser power, scanning speed and focus position and the specimens were characterised by comparing hardness, residual stresses and microstructure. The results showed that laser surface treatment changed the hardness profile of the near surface of the specimen owing to the introduction of a homogenous microstructure at the surface as compared to a friction welded specimen. The microstructure was resolved using electron backscatter diffraction. A fully α-lamella microstructure was observed in the two specimens analysed at a position of 200 μm from the surface. The α-lamella had different width sizes with the low-power density specimen having a very fine microstructure as compared to that of the high-power density specimen. EBSD phase maps were also analysed for the parent, rotary friction welded only and friction welded laser surface treated specimens. The laser treated specimens showed virtually no β phase present as compared to the parent and rotary friction welded only specimens. LST processing improved the fatigue properties of the RFW specimens. The position of failure shifted from the HAZ to outside the RFW joint. This change in position was attributed to the surface modification by LST thereby introducing a more homogenous microstructure at the surface of the specimen. Additionally, it was also observed that the power density had an important role to play in the fatigue properties of the laser surface treated specimens. The high-power density LST specimens had a low fatigue limit compared to the low-power density specimens. The low fatigue limit at high- power density correlated with the residual stress results where the high-power density specimen had the highest attained surface tensile axial residual stresses. In conclusion, the main influences of laser surface treatment of small friction welded Ti-6Al-4V ELI components relate to an increase in fatigue properties by shifting crack initiation sites to less stressed areas. In this way, laser surface treatment could assist in the optimisation of manufacturing methodologies for small near net shape complex geometry components. The uniform and homogenous microstructure eliminates or reduces microstructural variations as observed in as welded components, reducing weld zone hardness variation. Additionally, the study showed that the introduction of a near surface refined microstructure inhibited crack initiation in the welded region.
- Full Text:
- Date Issued: 2019
- Authors: Tsikayi, Davies Shamiso
- Date: 2019
- Subjects: Lasers -- Industrial applications , Friction welding Pressure welding Metals -- Research
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/43823 , vital:37050
- Description: This manuscript details a study on laser surface treatment, a surface modification technique that is an easily flexible way of improving material surface properties of complex geometries. The research explored the potential of laser surface modification/treatment as a post welding surface processing technique for RFW Ti-6Al-4V ELI components by evaluating the microstructural effects, influence on fatigue life and the depth and magnitude of residual stresses induced. The outcome of this study reveals how post processing by laser surface modification affects crack initiation hence fatigue life and further explains mechanisms potentially contributing to enhanced joint properties. This study was accomplished by investigating the effect of laser surface treatment on surface properties of hourglass cylindrical rotary friction welded Ti-6Al-4V ELI specimens. Preliminary work was done in two stages. The first stage involved conducting laser surface treatment on 3 mm Ti-6Al-4V sheets. In this stage, an understanding of the process variables concerning the laser surface treatment process characteristics was established. Laser power and focus position were varied whilst scanning speed was kept constant. The observed macrographs were quantified in terms of laser penetration depth and width. A hardness and microstructural analysis was also conducted on selected specimens of the laser surface treated flat sheets trials. The second stage involved surface treatment of the hourglass fatigue specimen. This preliminary work allowed for the type and influence of treatment strategy to be analysed. The influence of treatment strategy on the depth of penetration was established with an emphasis on achieving homogeneity of the laser surface treated zone’s depth of penetration around the complete cylindrical specimen’s diameter. The final matrix involved varying laser power, scanning speed and focus position and the specimens were characterised by comparing hardness, residual stresses and microstructure. The results showed that laser surface treatment changed the hardness profile of the near surface of the specimen owing to the introduction of a homogenous microstructure at the surface as compared to a friction welded specimen. The microstructure was resolved using electron backscatter diffraction. A fully α-lamella microstructure was observed in the two specimens analysed at a position of 200 μm from the surface. The α-lamella had different width sizes with the low-power density specimen having a very fine microstructure as compared to that of the high-power density specimen. EBSD phase maps were also analysed for the parent, rotary friction welded only and friction welded laser surface treated specimens. The laser treated specimens showed virtually no β phase present as compared to the parent and rotary friction welded only specimens. LST processing improved the fatigue properties of the RFW specimens. The position of failure shifted from the HAZ to outside the RFW joint. This change in position was attributed to the surface modification by LST thereby introducing a more homogenous microstructure at the surface of the specimen. Additionally, it was also observed that the power density had an important role to play in the fatigue properties of the laser surface treated specimens. The high-power density LST specimens had a low fatigue limit compared to the low-power density specimens. The low fatigue limit at high- power density correlated with the residual stress results where the high-power density specimen had the highest attained surface tensile axial residual stresses. In conclusion, the main influences of laser surface treatment of small friction welded Ti-6Al-4V ELI components relate to an increase in fatigue properties by shifting crack initiation sites to less stressed areas. In this way, laser surface treatment could assist in the optimisation of manufacturing methodologies for small near net shape complex geometry components. The uniform and homogenous microstructure eliminates or reduces microstructural variations as observed in as welded components, reducing weld zone hardness variation. Additionally, the study showed that the introduction of a near surface refined microstructure inhibited crack initiation in the welded region.
- Full Text:
- Date Issued: 2019
Characterizing the influence of process variables in laser cladding Al-20WT%Si onto an Aluminium Substrate
- Authors: Von Wielligh, Louis George
- Subjects: Lasers -- Industrial applications , Metal cladding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9625 , http://hdl.handle.net/10948/721 , Lasers -- Industrial applications , Metal cladding
- Description: The research investigated the application of continuous coaxial laser cladding by powder injection as a surface treatment or coating process. The investigation aimed to establish the relationship between a change in the main laser cladding process variables and the geometry and characteristics of an Al-20wt-Si single pass clad layer formed on an Al 1370-F substrate using a Nd:YAG laser. The main process variables considered were: laser power, laser scanning velocity and the powder feed rate. The relationship between a change in the main laser cladding process variables and the geometry and characteristics of the clad layer was established by statistically analysing the variation in the process response with a change in the main laser cladding process variables. The process variables were varied based on a full-factorial, experimentally optimized test matrix. The clad geometry which is mainly defined by: the clad height, width, clad aspect ratio, depth of alloy penetration, and the clad root angle/wetting angle was investigated. In addition to the clad geometry several clad characteristics were investigated such as the dilution of the clad layer in the substrate material, the Vickers microhardness and microstructure of the clad crosssection, the powder efficiency of the process and the amount of visible defects. The study successfully established the relationship between the main laser cladding process variables and the clad geometry and characteristics. The secondary objective of establishing a suitable processing window by considering the relationship mentioned above was only partially met since it is believed that further refinement of the experimental cladding test setup and therefore also the experimental variable test levels is required.
- Full Text:
- Authors: Von Wielligh, Louis George
- Subjects: Lasers -- Industrial applications , Metal cladding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9625 , http://hdl.handle.net/10948/721 , Lasers -- Industrial applications , Metal cladding
- Description: The research investigated the application of continuous coaxial laser cladding by powder injection as a surface treatment or coating process. The investigation aimed to establish the relationship between a change in the main laser cladding process variables and the geometry and characteristics of an Al-20wt-Si single pass clad layer formed on an Al 1370-F substrate using a Nd:YAG laser. The main process variables considered were: laser power, laser scanning velocity and the powder feed rate. The relationship between a change in the main laser cladding process variables and the geometry and characteristics of the clad layer was established by statistically analysing the variation in the process response with a change in the main laser cladding process variables. The process variables were varied based on a full-factorial, experimentally optimized test matrix. The clad geometry which is mainly defined by: the clad height, width, clad aspect ratio, depth of alloy penetration, and the clad root angle/wetting angle was investigated. In addition to the clad geometry several clad characteristics were investigated such as the dilution of the clad layer in the substrate material, the Vickers microhardness and microstructure of the clad crosssection, the powder efficiency of the process and the amount of visible defects. The study successfully established the relationship between the main laser cladding process variables and the clad geometry and characteristics. The secondary objective of establishing a suitable processing window by considering the relationship mentioned above was only partially met since it is believed that further refinement of the experimental cladding test setup and therefore also the experimental variable test levels is required.
- Full Text:
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