Increase of process reliability of ultra-precision cutting through direct temperature measurement in cutting parts form single crystal diamond by use of Boron-doping
Production Automation and Assembly Technology
Final Report Abstract
According to the state of the art, the current temperature measurement methods used show considerable limitations in terms of resolution accuracy GA and accessibility to the cutting-edge in the field of ultra-precision machining. Therefore, the temperature development during the machining process is not fully understood. The aim of this research project was to develop a dedicated temperature measurement system based on boron-doped single crystalline diamonds (BDD) as a temperature sensor for the highly sensitive detection of cutting temperatures ϑc in ultra-precision turning. The results achieved in the research project on the use of BDD as a temperature sensor in ultra-precision machining demonstrated the basic functionality and usability of the developed temperature sensor. As part of the investigations, the dependencies between the electro-sensory properties such as resistance R, doping level dlev, doping length dlen and temperature ϑ were identified and findings on the application of BDD were derived to use them for highly sensitive temperature measurements. Furthermore, a dedicated tool concept with suitable contacting methods and functional micro-electronics as well as a reliable and highly sensitive calibration routine were developed. Based on this, a fundamental experimental analysis of the process behaviour of the BDD during ultra-precise turning was carried out and its successful use as well as functionality as a highly sensitive temperature sensor could be demonstrated. Finally, simulations were carried out to derive the maximum temperatures on the cutting-edge ϑC,M based on a distance difference lA between the cutting-edge and the boron-doping. Based on the research project, a functional temperature measurement system was developed that enables the measurement of cutting temperatures ϑz in the field of ultra-precision machining with a significantly increased sensitivity compared to conventionally used temperature measurement methods. The influence of relevant factors such as accessibility to the cutting-edge, thermal conductivity λ, heat transfer coefficient hW , cutting material and material modification, which show a significant impact on temperature measurements, could be completely avoided or significantly reduced. This demonstrates the considerable potential for using ion-implanted BDD as temperature sensor, which will be further investigated in future research works.
Publications
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Direct temperature measurement in ultra-precision cutting by using conductive monocrystalline boron-doped diamond as cutting tool. Diamond Business 1 (2019), S. 6 - 10
Uhlmann, E.; Perfilov, I.; Frenzel, S.; Polte, M. & Polte, J.
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Boron-doped single crystal diamond for temperature measurement in the cutting zone. Special Interest Group Meeting: Micro/Nano Manufacturing, Euspen, Berlin, 27.11.2019
Uhlmann, E.; Polte, M.; Polte, J.; Kuche, Y. & Hocke, T.
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Boron-doped monocrystalline diamond as cutting tool for temperature measurement in the cutting zone. Procedia CIRP, 101(2021), 258-261.
Uhlmann, E.; Polte, J.; Polte, M. & Hocke, T.
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Characterisation and investigation of ionimplanted boron-doped single crystal diamonds as temperature sensor for ultra-precision machining. euspen´s 23nd International Conference & Exhibition, Copenhagen, DK, 2023, S. 63 – 64
Uhlmann, E.; Polte, M.; Hocke, T. & Thißen, K.
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Edge Computing Software für den Zerspanungsprozess/Edge computing software for the chipping process – Enabling data-intensive innovation in industry through open data and open source. wt Werkstattstechnik online, 113(07-08), 311-314.
Uhlmann, Eckart; Polte, Mitchel; Hocke, Toni & Heper, Martin
