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Diamond Turning of Glassy Polymers Diamond turning of glassy polymers Citation for published version (APA): Gubbels, G. P. H. (2006). Diamond turning of glassy polymers. Technische Universiteit Eindhoven. https://doi.org/10.6100/IR613637 DOI: 10.6100/IR613637 Document status and date: Published: 01/01/2006 Document Version: Publisher’s PDF, also known as Version of Record (includes final page, issue and volume numbers) Please check the document version of this publication: • A submitted manuscript is the version of the article upon submission and before peer-review. There can be important differences between the submitted version and the official published version of record. People interested in the research are advised to contact the author for the final version of the publication, or visit the DOI to the publisher's website. • The final author version and the galley proof are versions of the publication after peer review. • The final published version features the final layout of the paper including the volume, issue and page numbers. Link to publication General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. • Users may download and print one copy of any publication from the public portal for the purpose of private study or research. • You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal. If the publication is distributed under the terms of Article 25fa of the Dutch Copyright Act, indicated by the “Taverne” license above, please follow below link for the End User Agreement: www.tue.nl/taverne Take down policy If you believe that this document breaches copyright please contact us at: [email protected] providing details and we will investigate your claim. Download date: 07. Oct. 2021 Diamond Turning of Glassy Polymers Guido Gubbels Diamond Turning of Glassy Polymers Guido P.H. Gubbels 21st August 2006 Gubbels, Guido P.H. Diamond Turning of Glassy Polymers by Guido P.H. Gubbels – Eindhoven: Technische Universiteit Eindhoven, 2006. Proefschrift. A catalogue record is available from the Library Eindhoven University of Tech- nology ISBN-10: 90-386-2918-4 ISBN-13: 978-90-386-2918-6 NUR 978 Subject headings: diamond turning / glassy polymers / thermal modelling / sur- face / tribo-electric tool wear / tribo-chemical tool wear / oxidative etching This thesis was prepared with the LATEX2ε documentation system. Printed by PrintPartners Ipskamp, Enschede, The Netherlands. Cover: Lichtenberg figure through the diamond tool. Copyright © 2006 by G.P.H. Gubbels All rights reserved. No parts of this publication may be reproduced, utilised or stored in any form or by any means, electronic or mechanical, including pho- tocopying, recording or by any information storage and retrieval system, without permission of the copyright holder. Diamond Turning of Glassy Polymers PROEFSCHRIFT ter verkrijging van de graad van doctor aan de Technische Universiteit Eindhoven, op gezag van de Rector Magnificus, prof.dr.ir. C.J. van Duijn, voor een commissie aangewezen door het College voor Promoties in het openbaar te verdedigen op dinsdag 31 oktober 2006 om 16.00 uur door Guido Petrus Herman Gubbels geboren te Urmond Dit proefschrift is goedgekeurd door promotor: prof.dr.ir. P.H.J. Schellekens Copromotoren: dr.ir. F.L.M. Delbressine en dr.ir. L.E. Govaert Dedicated to Astrid, Lieke and Thomas and my parents vi Samenvatting De optische industrie krijgt steeds grotere interesse in de toepassing van kunst- stoffen als optische componenten. De reden hiervoor is dat er kunststoffen met steeds hogere brekingsindex ontwikkeld worden en dat deze bovendien een lagere soortelijke massa hebben dan glas. Het is mogelijk om kunststoffen tot optische kwaliteit te draaien in e´en´ opspanning: dit is een proces dat in de contactlenzen- industrie al toegepast wordt. De voordelen hiervan zijn kostenbesparing, omdat er minder machines nodig zijn en verhoogde nauwkeurigheid door afwezigheid van omstelfouten. In dit onderzoek is gekeken naar het precisiedraaiproces van glasachtige (transparante) kunststoffen. In het algemeen worden voor het precisiedraaien mono-kristallijne diamantbeitels gebruikt. Voor procesoptimalisatie van het ver- spaningsproces van kunststoffen is het van groot belang dat men weet in welke fase zich het kunststof bevindt tijdens het draaien en hoe de relatief hoge dia- mantslijtage ontstaat. In de literatuur op het gebied van precisiedraaien van kunststoffen wordt aangenomen dat men de beste oppervlaktekwaliteit behaalt als men een tempe- ratuurstijging tot de glastransitietemperatuur (Tg) van het polymeer kan bereiken door meer adiabatische verspaningscondities toe te passen. De oppervlakte- kwaliteit werd in alle onderzoeken direct gekoppeld aan het wel of niet bereiken van Tg. Ook zijn er afschattingen van de temperatuurstijging gemaakt tijdens het verspanen, maar hiervoor zijn nooit daadwerkelijk krachtmetingen uitgevoerd. In het eerste deel van deze dissertatie wordt het aangepaste temperatuurmo- del van Hahn toegepast. De invoer voor dit model zijn de verspaningskrachten, die in dit onderzoek daadwerkelijk gemeten zijn. De belangrijkste aanpassing van het temperatuurmodel voor dit onderzoek bestaat uit de toevoeging van de conversieratio η van mechanische arbeid naar warmte. Op basis van literatuur en uitgevoerde temperatuurmetingen blijkt dat deze voor kunststoffen op 0,5 gesteld mag worden tijdens het verspaningsproces. Door toepassing van het temperatuurmodel blijkt dat de temperatuur tijdens het verspaningsproces van kunststoffen niet de glastransitietemperatuur bereikt. Dit geeft aan dat de behaalde oppervlaktekwaliteit na diamantdraaien niet be- invloed wordt door de hoogte van Tg. Een andere implicatie is dat naast ther- misch geactiveerde vloei een deel spanningsgeactiveerde vloei optreedt tijdens vii viii Samenvatting het verspanen. De spanningsgeactiveerde vloei kan ketenbreuk in de primaire de- formatiezone tot gevolg hebben, wat bij PMMA het geval is en bij polycarbonaat (PC) niet. Het temperatuurmodel is ook gebruikt voor de bestudering van de invloed van diverse verspaningsparameters. Hieruit blijkt bijvoorbeeld dat een verhoging van de snijsnelheid weinig invloed heeft op de maximale temperatuur in de primaire deformatiezone. Wel leidt een grote negatieve spaanhoek (−20◦) tot een aanzienlijke temperatuurstijging. Echter, deze is ook niet voldoende om Tg te bereiken tijdens het draaien van PC. Zowel gestoken als vlakgedraaide oppervlakken zijn bestudeerd. De opper- vlakken na het steken (met een rechte snijkant) van PC vertoonden sterke over- eenkomsten met plooien gevormd in een viskeuze laag op een viskeuze matrix belast onder compressie. PMMA vertoonde dit gedrag niet, wat verklaard kan worden door het feit dat PMMA een gesegmenteerde spaan vormt en PC een volledig ductiele spaan. Alhoewel plooivorming een significante invloed kan hebben op de opper- vlakteruwheid tijdens steken, is dit effect verwaarloosbaar bij het precisiedraaien met radiusbeitels vanwege de zeer kleine spaandoorsnedes. Het blijkt dat de oppervlakteruwheid van precisiegedraaide kunststof oppervlakken gedomineerd wordt door de beitelafdruk en optimalisatie kan hier het beste toegepast worden middels aanpassing van de voeding. De thermo-mechanische geschiedenis van een kunststof is niet van invloed op de haalbare oppervlaktekwaliteit. Daarnaast blijkt ook de crosslinkdichtheid ge´en´ direkte factor voor haalbare oppervlaktekwaliteit te zijn. Dit is onderzocht met behulp van verschillend gecrosslinkte PMMA materialen. Weliswaar veranderde de oppervlaktestructuur bij toenemende crosslinkdichtheid, maar de Ra waarde bleef nagenoeg gelijk. Het lijkt erop dat niet zonder meer verondersteld mag worden dat thermoharders niet tot optische kwaliteit te verspanen zijn. Het tweede deel van deze dissertatie beschrijft de twee dominante slijtage- mechanismen tijdens het diamantdraaien van kunststoffen. Voor tribo-elektrische slijtage is een sterke oplading nodig met een bepaalde polariteit. Als de beitel als anode fungeert kunnen positieve Lichtenberg figuren in de beitel ontstaan. Als de beitel als kathode fungeert, zijn er veel grotere veldsterktes nodig om Lichtenberg figuren te laten ontstaan. Hierdoor hoeft tribo-elektrische slijtage dan niet als het dominante slijtagemechanisme aanwezig te zijn. Een ander dominant slijtagemechanisme is tribo-chemische slijtage. Experi- menten hebben duidelijk gemaakt dat het hier om een oxidatief etsproces gaat. Dit etsen leek alleen op te treden bij kunststoffen die makkelijk hydrolyseerbaar zijn. Als spaanvlak wordt veelal de (110) orientatie¨ gebruikt, welke naar een (111) vlak toeetst.¨ De invloed van de relatieve luchtvochtigheid is hierbij een belang- rijke parameter en dit duidt op een OH-stabilisatie tijdens het etsen. Er is een reactiemechanisme opgesteld voor de oxidatie tijdens het diamantdraaien van kunststoffen met als basis een nucleofiele aanval op een carbonyl getermineerd ix diamantoppervlak, uiteindelijk resulterend in CO-desorptie en OH-terminatie aan het diamantoppervlak. Op deze manier kan etsen als dominant slijtageme- chanisme optreden. Berekeningen hebben aangetoond dat er voldoende energie vrijkomt om dit etsproces te laten verlopen en dat er ook voldoende nucleofielen aanwezig zijn om dit proces
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