Ultrasonic-assisted deep hole grinding of alumina ceramics with laser surface micro-structured brazed diamond tools
摘要
Alumina ceramic deep holes have significant potential in high-end manufacturing fields such as aerospace and semiconductors. However, traditional mechanical machining technologies are limited by challenges in precision control and process flexibility. To address these issues, a novel surface micro-structured brazed diamond grinding tool is proposed in this paper. First, approximately trapezoidal linear micro-structure arrays were fabricated on the end and side surfaces of the tool utilizing a femtosecond laser ablation technique combining long and short pulses. Subsequently, comparative experiments between micro-structured and common tools were conducted under ultrasonic vibration-assisted deep hole grinding to systematically investigate the effects of surface micro-structures on grinding force, grinding force ratio, hole quality, and tool wear characteristics. The experimental results demonstrate that micro-structured tools provide significantly superior machining performance. Specifically, micro-structured tools achieved a threefold extension in the stable machining phase, while simultaneously increasing the grinding force ratio by 112.7%, reducing the inner surface roughness by 44.1%, and doubling the effective tool life from 11 to 22 holes. The results indicate that laser-induced micro-structuring of brazed diamond tools can effectively enhance grinding performance, improve surface integrity, and realize efficient, low-damage machining of alumina ceramic deep holes.