This paper presents a combined experimental and computational investigation of a novel material separation mechanism in polycrystalline diamond (PCD) substrates. A hybrid CO2 laser/waterjet (CO2-LWJ) machining system that combines a CO2 laser for localized heating and an abrasive-free waterjet to rapidly quench the heated area is utilized for cutting experiments on PCD substrates. Scanning electron microscopy (SEM) and micro-Raman spectrometry characterization performed on the cut surfaces show that cut surfaces were divided into two zones—a thin transformed zone near the top where the PCD grains have transformed to graphite and diamond-like carbon; and a fracture zone with the same composition as-received substrate. The experimental results indicate that the PCD substrates were cut through a “score and snap” mechanism—laser heating leads to localized damage and phase transformation of surface layers; and subsequently, stress fields developed due to constrained expansion of transformed material and waterjet quenching act on the laser made “score” to propagate crack through the thickness. Analytical solutions for thermal diffusion and force equilibrium are used to determine the temperature and stress fields in the PCD substrate during CO2-LWJ cutting. Fracture mechanics analysis of crack propagation is performed to demonstrate the feasibility of the “score and snap” mechanism for cutting of PCD substrates.
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August 2014
Research-Article
Hybrid CO2 Laser/Waterjet Machining of Polycrystalline Diamond Substrate: Material Separation Through Transformation Induced Controlled Fracture
Dinesh Kalyanasundaram,
Dinesh Kalyanasundaram
Centre for Biomedical Engineering,
Indian Institute of Technology Delhi
,Hauz Khas, New Delhi 110016
, India
Department of Mechanical Engineering,
Iowa State University
,Ames, IA 50011
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Andrea Schmidt,
Andrea Schmidt
Department of Mechanical Engineering,
Iowa State University
,Ames, IA 50011
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Pal Molian,
Pal Molian
Department of Mechanical Engineering,
Iowa State University
,Ames, IA 50011
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Pranav Shrotriya
Pranav Shrotriya
1
Department of Mechanical Engineering,
e-mail: shrotriya@iastate.edu
Iowa State University
,Ames, IA 50011
e-mail: shrotriya@iastate.edu
1Corresponding author.
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Dinesh Kalyanasundaram
Centre for Biomedical Engineering,
Indian Institute of Technology Delhi
,Hauz Khas, New Delhi 110016
, India
Department of Mechanical Engineering,
Iowa State University
,Ames, IA 50011
Andrea Schmidt
Department of Mechanical Engineering,
Iowa State University
,Ames, IA 50011
Pal Molian
Department of Mechanical Engineering,
Iowa State University
,Ames, IA 50011
Pranav Shrotriya
Department of Mechanical Engineering,
e-mail: shrotriya@iastate.edu
Iowa State University
,Ames, IA 50011
e-mail: shrotriya@iastate.edu
1Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received June 23, 2011; final manuscript received February 28, 2014; published online May 21, 2014. Assoc. Editor: Allen Y. Yi.
J. Manuf. Sci. Eng. Aug 2014, 136(4): 041001 (10 pages)
Published Online: May 21, 2014
Article history
Received:
June 23, 2011
Revision Received:
February 28, 2014
Citation
Kalyanasundaram, D., Schmidt, A., Molian, P., and Shrotriya, P. (May 21, 2014). "Hybrid CO2 Laser/Waterjet Machining of Polycrystalline Diamond Substrate: Material Separation Through Transformation Induced Controlled Fracture." ASME. J. Manuf. Sci. Eng. August 2014; 136(4): 041001. https://doi.org/10.1115/1.4027304
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