Simple machining method for ceramic cone structure with middle interlayer

Abstract

The invention discloses a simple manufacturing method of a ceramic cone with a middle interlayer, which comprises the following steps of: clamping and fixing a ceramic round rod blank, and ensuring that the clamping force is uniform to prevent the breakage caused by stress concentration; angle adjustment is conducted for the first time, a shallow-angle cutting datum plane is established, and a workbench is rotated to 1 / 4 of the designed cone angle theta of the ceramic cone; starting a dual-motor system, and synchronously rotating to ensure the grinding uniformity; primary Y-direction grinding is conducted, specifically, Y-direction feeding is conducted, and a second motor is ground to the first required length L; secondary angle adjustment is carried out, and the workbench is rotated to 1 / 2 of the designed cone angle theta of the ceramic cone; secondary Y-direction grinding is carried out, and a second motor is fed in the Y direction to be ground to a second required length L2; and X-direction finish machining and detection are carried out, so that the surface smoothness meets the requirement. The method is simple, the requirement for equipment is low, the method is achieved on a common grinding machine, and the equipment threshold is reduced by 80%; and high precision can be guaranteed, and meanwhile it is guaranteed that the interlayer is located in the middle of the cone top.

Description

Technical Field

[0001] This invention relates to the field of precision ceramic processing technology, specifically, to a simple processing method for a ceramic cone structure with an intermediate sandwich layer. Background Technology

[0002] Matching ceramics are used in Faraday isolators. In Faraday isolators, matching ceramics reduce the reflection and refraction of electromagnetic waves at the interface, and also reduce the size of the device. The degree of eccentricity of the matching ceramic affects the device's performance. To ensure good performance, the resistive film sandwiched between the cone's bottom and top must be positioned during the ceramic cone's fabrication process. Due to their high brittleness, low fracture toughness, and high hardness, ceramic materials are prone to fracture, chipping, cracking, and surface damage during processing.

[0003] For example, patent CN107891318A - a ceramic ferrule outer diameter machining mechanism, which uses high-precision CNC milling machines, centerless grinders and other methods to achieve the machining purpose and requirements, has high requirements for machining equipment and complex machining process. Summary of the Invention

[0004] To address the aforementioned technical problems, the present invention aims to provide a simple processing method for a ceramic cone structure with an intermediate interlayer. The cone is processed by graded angle grinding, which reduces the possibility of material breakage and ensures that the interlayer is located in the middle of the cone apex. The method is simple and effective.

[0005] The present invention solves the above problems through the following technical solution:

[0006] A simple method for manufacturing a ceramic cone with an intermediate sandwich layer includes:

[0007] Step A: Clamp and fix the ceramic round rod blank, and ensure that the clamping force is uniform to prevent stress concentration from causing breakage;

[0008] Step B: Initial angle adjustment, establish a shallow angle cutting reference surface, and rotate the worktable to 1 / 4 of the design cone angle θ of the ceramic cone;

[0009] Step C: Start the dual-motor system and rotate synchronously to ensure uniform grinding;

[0010] Step D: Initial Y-axis grinding, the second motor feeds in the Y-axis to grind to the first required length L1;

[0011] Step E: Secondary angle adjustment, rotate the worktable to 1 / 2 of the designed cone angle θ of the ceramic cone;

[0012] Step F: Secondary Y-axis grinding, the second motor feeds in the Y-axis to grind to the second required length L2;

[0013] Steps G and X involve finishing and inspection to ensure the surface finish meets requirements.

[0014] As a further improvement, step A includes:

[0015] The second motor with a three-jaw chuck is mounted on the worktable, and the first motor with a diamond grinding wheel head is mounted outside the worktable and facing the center of the worktable.

[0016] The ceramic cylindrical blank is then placed in the second motor with a three-jaw chuck to clamp and fix the ceramic cylindrical blank.

[0017] As a further improvement, in step A, the clamping torque applied to the ceramic rod is 5-15 Nm, and the coaxiality between the axis of the ceramic rod and the grinding spindle of the first motor is ≤0.1 mm.

[0018] As a further improvement, the ceramic rod has a diameter of 0.5-4 mm and a length of 5-15 mm.

[0019] As a further improvement, the method of step B includes:

[0020] Based on the design requirements of the ceramic cone, the cone angle θ is calculated using the diameter of the cone's base and its height.

[0021] The control table is rotated until the angle between the centerline of the first motor and the center of the ceramic rod on the second motor is θ / 4, with an error of ±0.1°.

[0022] As a further improvement, the formula for calculating the cone angle θ is:

[0023] θ = 2arctan(D / 2H);

[0024] Where D is the diameter of the ceramic cone's base, and H is the height of the ceramic cone.

[0025] As a further improvement, the second motor speed n and the first motor feed speed V_f satisfy: n = k·V_f, where k is the material coefficient.

[0026] As a further improvement, the first required length L1 is 70%-85% of the target total length, and the feed amount in the y direction each time is 0.25-1mm.

[0027] As a further improvement, the second required length L2 is the target total length tolerance of ±0.05mm.

[0028] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0029] The method of this invention is simple and has low equipment requirements, and can be implemented on a regular grinding machine, reducing the equipment threshold by 80%; it can also ensure high precision while ensuring that the interlayer is in the middle of the cone apex.

[0030] The cone base diameter of this invention can be controlled within an error of ≤0.05mm, and the maximum deviation in cone height accuracy is only 0.05mm. This invention, through graded processing, can completely eliminate ceramic microcracks. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the ceramic cone with an intermediate interlayer of the present invention;

[0032] Figure 2 This is a schematic diagram of the ceramic cone processing of the present invention;

[0033] Figure 3 This is a schematic diagram of the installation of the first motor and the second motor of the present invention;

[0034] Figure 4 This is a flowchart illustrating a simplified manufacturing method for a ceramic cone with an intermediate interlayer according to the present invention. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The described embodiments are some, but not all, of the embodiments of this application. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0036] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0037] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an indirect connection through an intermediate medium, or the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0038] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, product, or display that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or display.

[0039] The following will combine Figure 1-4 This application provides a detailed description of a simplified method for manufacturing a ceramic cone with an intermediate interlayer, as described in the embodiments of this application. It is worth noting that the following embodiments are merely illustrative of this application and do not constitute a limitation thereof.

[0040] Example 1:

[0041] See attached document Figure 1-4 This embodiment provides a simplified method for manufacturing a ceramic cone with an intermediate interlayer, comprising the following steps:

[0042] Step 1: Clamp and fix the ceramic round rod blank, and ensure that the clamping force is uniform to prevent stress concentration from causing breakage;

[0043] First, install the second motor with a three-jaw chuck on the worktable, and install the first motor with a diamond grinding wheel head outside the worktable and facing the center of the worktable.

[0044] The ceramic round bar blank is then placed in the second motor with a three-jaw chuck. By uniformly applying a clamping torque of 5-15 Nm, the coaxiality between the ceramic round bar axis and the grinding machine spindle is ensured to be ≤0.1 mm.

[0045] In this embodiment, preferably, the diameter of the ceramic rod is 0.5-2mm and the length of the ceramic rod is 5-15mm.

[0046] Step 2: Establish a shallow angle cutting reference surface for the first time, and rotate the worktable to 1 / 4 of the design cone angle θ of the ceramic cone;

[0047] 2.1) Based on the design requirements of the ceramic cone, calculate the cone angle θ using the diameter and height of the cone's base.

[0048] In this embodiment, θ = 2arctan(D / 2H), where D is the diameter of the ceramic cone's base and H is the height of the ceramic cone.

[0049] In this embodiment, preferably, the rotation angle of the worktable is 1° to 10°.

[0050] 2.2) Control the worktable to rotate until the angle between the centerline of the first motor and the center of the ceramic round blank on the second motor is θ / 2, with an error of ±0.1°.

[0051] Step 3: Start the dual-motor system and rotate synchronously to ensure uniform grinding;

[0052] In this system, the centerline of the ceramic rod on the second motor is the X-direction, and the plane parallel to the rotation plane of the worktable and perpendicular to the X-direction is the Y-direction. The Y-direction feeds the second motor to perform grinding. Turn on the first motor and adjust its speed to 7000-9000 rpm; turn on the second motor and adjust its speed to 2000-4000 rpm.

[0053] 3.1) Start the first motor: drive the diamond grinding wheel with a grit size of #600-#1200 to rotate at a linear speed of 15-30m / s, which can avoid the contradiction between tool wear and processing efficiency caused by the high hardness of ceramics.

[0054] 3.2) Turn on the second motor: drive the three-jaw chuck to rotate at a speed of 2000-4000 rpm, which can avoid the risk of edge cracking caused by ceramic brittleness.

[0055] Preferably, in this embodiment, the rotational speed n of the second motor and the feed speed V_f of the first motor satisfy: n = k·V_f, where k is a material coefficient. Through rotational speed-feed coupling, the grinding force direction is always through the ceramic axis.

[0056] Step 4: Initial Y-axis grinding, the second motor feeds in the Y-axis to grind to the first required length L1;

[0057] 4.1) The speed of the second motor for Y-axis feed is 0.5-2 mm / min;

[0058] 4.2) Grind to the first required length L1, where L1 is 70%-85% of the target total length. For example, if the total length is 20mm, grind to 14-17mm to initially form a conical profile.

[0059] In this embodiment, preferably, the feed amount in the y direction is 0.25-1mm.

[0060] Step 5: Second angle adjustment, rotate the worktable to 1 / 2 of the designed cone angle θ of the ceramic cone;

[0061] In this embodiment, preferably, the rotation angle of the worktable is 2° to 20°.

[0062] Step 6: Secondary Y-axis grinding, the second motor feeds in the Y-axis to grind to the second required length L2, completing the main conical structure;

[0063] 6.1) The Y-axis feed rate is reduced to 0.2-1 mm / min;

[0064] 6.2) Grind to the second required length L2, where L2 is the target total length tolerance ±0.05mm.

[0065] In this embodiment, preferably, the feed amount in the y direction is 0.25-1mm.

[0066] Step 7: X-axis finishing and inspection to ensure surface finish meets requirements.

[0067] 7.1) X-axis radial feed: 0.01-0.05 mm / time

[0068] 7.2) Repeat the cycle 3-5 times until the surface roughness Ra ≤ 1 μm

[0069] 7.3) Monitor the interlayer position in real time, with a centering deviation of ≤0.05mm.

[0070] In this embodiment, preferably, the feed amount in the x-direction is 0.1-2 mm.

[0071] The ceramic cone produced by the simplified manufacturing method of the ceramic cone with an intermediate interlayer of the present invention has a fracture rate that is reduced by more than 40% compared with that of traditional continuous grinding ceramics; the centering deviation of the interlayer is ≤0.05mm, which meets the requirements of laser-grade Faraday isolators; it can be produced on ordinary cylindrical grinding machines, reducing equipment costs by 60%.

[0072] Example 2

[0073] Conical base 1.50mm × height 7.00mm:

[0074] Step 1: Blank clamping:

[0075] If the requirement is a ceramic cone with a base diameter of 1.5mm and a height of 7mm and an intermediate layer, take a ceramic rod with a diameter of 1.5mm and a length of 11mm and an intermediate layer. Fix one end of the rod with a three-jaw chuck with a fixing depth of 3mm and a clamping force of 10N·m.

[0076] Step 2: Initial angle setting;

[0077] The cone angle θ = 2arctan(1.5 / (2×7)) = 12.22°, and the worktable rotates to θ / 4 of the cone angle, which is 3.06°;

[0078] Step 3: Start both motors; turn on the first motor and adjust the speed to 8000 rpm; turn on the second motor and adjust the speed to 3000 rpm;

[0079] Step 4: Initial Y-axis grinding; Y-axis feed rate 0.32mm, feed rate 0.05mm each time, grind to 6.0mm, leave 1.0mm margin; after the feed is completed, retract the second motor and rotate the worktable back to the cone angle θ / 2.

[0080] Step 5: Angle adjustment; rotate the worktable to 6.12°;

[0081] Step 6: Secondary Y-axis grinding; turn on the first motor and adjust the speed to 8000 rpm; turn on the second motor and adjust the speed to 3000 rpm; start calculating the feed rate when the bar stock just contacts the grinding wheel, the feed rate in the Y direction is 0.75mm, and each feed is 0.05mm, until it is ground to 7.00mm;

[0082] Step 7: X-axis finishing; feed 0.2mm in the x-direction, with each feed increment being 0.05mm;

[0083] After removing the second motor and removing the bar stock, the excess portion is cut off to obtain a ceramic cone with a bottom diameter of 1.5 mm and a height of 7 mm and an intermediate interlayer.

[0084] Test results:

[0085] project Measured value Standards Cone base diameter 1.502mm 1.50±0.01 Surface roughness Ra 0.8μm ≤1μm Roundness error 0.07mm ≤0.1mm crack none none Cone height error -0.012mm 7.00±0.03mm

[0086] Example 3:

[0087] Conical base 1.25mm × height 5.0mm:

[0088] Step 1: Blank clamping; Insert the Φ2.0mm silicon nitride ceramic round bar into the three-jaw chuck, apply a clamping force of 8N·m, and the radial runout ≤0.01mm;

[0089] Step 2: Initial angle setting; Calculate the cone angle: θ = 2arctan(1.25 / (2×5)); Rotate the worktable to θ / 4 of the cone angle, i.e., 3.56°;

[0090] Step 3: Start the dual-motor system; turn on the first motor and adjust the speed to 8000 rpm; turn on the second motor and adjust the speed to 3000 rpm;

[0091] Step 4: Initial Y-axis grinding: Y-axis feed speed 0.8mm / min, feed 0.05mm each time; grind length up to 4.2mm, leave 0.8mm margin; after feed is complete, retract the second motor and rotate the worktable back to the cone angle θ / 2.

[0092] Step 5: Secondary angle adjustment; worktable to 7.13°;

[0093] Step 6: Secondary Y-axis grinding; turn on the first motor and adjust the speed to 8000 rpm; turn on the second motor and adjust the speed to 3000 rpm; Y-axis feed speed 0.3 mm / min, feed 0.05 mm each time, grind to the final length of 5.00 mm;

[0094] Step 7: X-axis finishing; X-axis radial feed 0.005mm / time, cycle 5 times; disengage the second motor, remove the bar stock, and cut off the excess.

[0095] Test results:

[0096] project Measured value Standards Cone base diameter 1.251mm 1.25±0.01 Surface roughness Ra 0.9μm ≤1μm Roundness error 0.08mm ≤0.1mm crack none none Cone height error +0.02mm 5.00±0.03mm

[0097] Example 4

[0098] Conical base 2.5mm × height 5.54mm:

[0099] Step 1: Blank clamping: Φ4.0mm zirconia ceramic, clamping force 12N·m;

[0100] Step 2: Initial angle setting: θ = 2arctan[2.5 / (2×5.54)] = 25.44°, rotate to θ / 4, i.e. 6.36°;

[0101] Step 3: Dual motor start: Turn on the first motor and adjust the speed to 8000 rpm; turn on the second motor and adjust the speed to 3000 rpm;

[0102] Step 4: Initial Y-axis grinding: feed 1.5mm / min, feed 0.05mm each time, grind to 4.8mm, leave 0.74mm; after the feed is completed, retract the second motor and rotate the worktable back to the cone angle θ / 2.

[0103] Step 5: Angle adjustment: Rotate the worktable to 12.72°;

[0104] Step 6: Secondary Y-axis grinding: Turn on the first motor and adjust the speed to 8000 rpm; turn on the second motor and adjust the speed to 3000 rpm; start calculating the feed rate when the bar stock just contacts the grinding wheel, feed at 0.5 mm / min to grind to 5.54 mm;

[0105] Step 7: X-axis finishing: 0.02mm / time × 3 times; Exit motor 2, remove the bar stock, and cut off the excess.

[0106] Test results:

[0107] project Measured value Standards Cone base diameter 2.503mm 2.50±0.01 Surface roughness Ra 0.85μm ≤1μm Roundness error 0.08mm ≤0.1mm crack none none Cone height error +0.025mm 5.54±0.03mm

[0108] Experiments have shown that the cone bottom diameter is controlled with an error of ≤0.01mm. Through staged grinding and stress release, no cracks were found in any of the embodiments. The cone height accuracy deviation is less than 0.03mm, which is 0.54% of the design value. It meets the standard 100% in various materials such as alumina, silicon nitride, and silicon carbide.

[0109] Although the present invention has been described herein with reference to illustrative embodiments, the above embodiments are merely preferred embodiments of the present invention, and the implementation of the present invention is not limited to the above embodiments. It should be understood that those skilled in the art can devise many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A simplified method for manufacturing a ceramic cone with an intermediate interlayer, characterized in that, include: Step A: Clamp and fix the ceramic round rod blank, and ensure that the clamping force is uniform to prevent stress concentration from causing breakage; Step B: Initial angle adjustment, establish a shallow angle cutting reference surface, and rotate the worktable to 1 / 4 of the design cone angle θ of the ceramic cone; Step C: Start the dual-motor system and rotate synchronously to ensure uniform grinding; Step D: Initial Y-axis grinding, the second motor feeds in the Y-axis to grind to the first required length L1; Step E: Secondary angle adjustment, rotate the worktable to 1 / 2 of the designed cone angle θ of the ceramic cone; Step F: Secondary Y-axis grinding, the second motor feeds in the Y-axis to grind to the second required length L2; Steps G and X involve finishing and inspection to ensure the surface finish meets requirements.

2. The simplified manufacturing method of a ceramic cone with an intermediate interlayer according to claim 1, characterized in that, Step A includes: The second motor with a three-jaw chuck is mounted on the worktable, and the first motor with a diamond grinding wheel head is mounted outside the worktable and facing the center of the worktable. The ceramic cylindrical blank is then placed in the second motor with a three-jaw chuck to clamp and fix the ceramic cylindrical blank.

3. The simplified manufacturing method of a ceramic cone with an intermediate interlayer according to claim 2, characterized in that, In step A, the clamping torque applied to the ceramic rod is 5-15 Nm, and the coaxiality between the axis of the ceramic rod and the grinding spindle of the first motor is ≤0.1 mm.

4. The simplified manufacturing method of a ceramic cone with an intermediate interlayer according to claim 1, characterized in that, The ceramic rod has a diameter of 0.5-4 mm and a length of 5-15 mm.

5. A simplified method for manufacturing a ceramic cone with an intermediate interlayer according to claim 1, characterized in that, The method in step B includes: Based on the design requirements of the ceramic cone, the cone angle θ is calculated using the diameter of the cone's base and its height. The control table is rotated until the angle between the centerline of the first motor and the center of the ceramic rod on the second motor is θ / 4, with an error of ±0.1°.

6. A simplified method for manufacturing a ceramic cone with an intermediate interlayer according to claim 5, characterized in that, The formula for calculating the cone angle θ is: θ = 2arctan(D / 2H); Where D is the diameter of the ceramic cone's base and H is the height of the ceramic cone.

7. A simplified method for manufacturing a ceramic cone with an intermediate interlayer according to claim 5, characterized in that, In step C, the dual-motor system is started, the first motor is turned on and the speed is adjusted to 7000-9000 rpm; the second motor is turned on and the speed is adjusted to 2000-4000 rpm.

8. A simplified method for manufacturing a ceramic cone with an intermediate interlayer according to claim 1, characterized in that, The second motor speed n and the first motor feed speed V_f satisfy: n = k·V_f, where k is the material coefficient.

9. A simplified method for manufacturing a ceramic cone with an intermediate interlayer according to claim 1, characterized in that, The first required length L1 is 70%-85% of the target total length, and the feed amount in the y direction each time is 0.25-1mm.

10. A simplified method for manufacturing a ceramic cone with an intermediate interlayer according to claim 1, characterized in that, The second required length L2 is the target total length tolerance of ±0.05mm.

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