Superposition of cryogenic and ultrasonic assisted machining of Zerodur

Abstract

Cryogenic machining is a cooling strategy that has recently been frequently found in research in machining processes for materials such as inconel or titanium. In particular it is reported that these processes are more efficient in terms of tool life and material removal rate compared to those with water-based cooling lubrication. An increase in efficiency and productivity has significant potential from a cost perspective, especially when grinding Ceramic Matrix Composite materials and similar. These processes are used, for example, in the lightweighting of telescope mirrors made of e.g. fiber-reinforced silicon carbide, or Zerodur. An increase in productivity would be clearly noticeable in the manufacturing costs due to normally long machining times. In the "KryoSonic" project, we investigated whether and to what extent the use of cryogenic machining affects the rough machining of Zerodur with and without ultrasonic support.