Rough cutting of germanium with polycrystalline diamond tools

Yergök, Çağlar
Germanium is a brittle semi-metal, used for lenses and windows in Thermal Imaging Systems since it transmits infrared energy in the 2 µm - 12 µm wavelength range at peak. In this thesis study, polycrystalline diamond is used as cutting tool material to machine germanium. Diamond is the hardest, most abrasion-resistant material and polycrystalline diamond is produced by compacting small diamond particles under high pressure and temperature conditions, which results more homogeneous, improved strength and a durable material. However, slightly reduced hardness is obtained when compared with natural diamond. Different from finish cutting, rough cutting, performed before finishing, is used to remove most of the work-piece material. During rough cutting, surface roughness is still an important concern, since it affects the finishing operations. Roughness of the surface of product is affected by a number of factors such as cutting speed, depth of cut, feed rate as cutting parameters, and also rake angle as tool geometry parameter. In the thesis, the optimum cutting and tool geometry parameters are investigated by experimental studies for rough cutting of germanium with polycrystalline diamond tools. Single Point Diamond Turning Machine is used for rough cutting, and the roughness values of the optical surfaces are measured by White Light Interferometer. Experiments are designed by making use of “Full Factorial” and “Box-Behnken” design methods at different levels considering cutting parameters as cutting speed, depth of cut, feed rate and tool geometry parameter as rake angle.
Citation Formats
Ç. Yergök, “Rough cutting of germanium with polycrystalline diamond tools,” M.S. - Master of Science, Middle East Technical University, 2010.