Design And Experimental Research Of Ultra-precision Fly-cutting Processing Suction Chip Exhaust System

KDP(KH ₂PO₄)crystal is an important optical component of solid-state lasers in inertial confinement nuclear fusion,and its processing quality plays an important role in improving the performance of solid-state lasers.However,the KDP crystal ultra-precision fly-cutting processing technology and equipment currently used in China will cause defects such as bumps and surface scratches on the processed surface.So it is difficult to efficiently and stably obtain crystal elements that meet the requirements.This article designed a KDP crystal chip suction type chip removal system for the above problems.The specific research content is as follows:Firstly,the existing KDP fly-cutting processing system and process were analyzed,and the chip formation mechanism of KDP crystals was studied based on the physical properties,intrinsic model and mechanical properties of KDP crystals.And the conditions of non-destructive surface formation of KDP crystals were derived.Based on the study of KDP crystal chip morphology,a chip classification method was proposed,and a general scheme of a suction-type chip removal system for ultra-precision fly-cutting machining was designed.Secondly,based on the pneumatic conveying theory,the resistance of particles in the suspension process was analyzed,the suspension velocity calculation models of different particle diameters were established,and the relationship between the particle diameter and its suspension velocity function was fitted and analyzed.According to the theoretical value of the maximum particle suspension velocity,the pipeline pressure drop and the inlet and outlet pressure difference were calculated through fluid simulation analysis and used as the basis for selecting the negative pressure fan.Thirdly,the simulation analysis of the flow field around the diamond tool during the fly-cutting process of KDP crystal was carried out.According to the maximum chip suspension critical speed,the fluid flow rate and pressure distribution law were used to compare and analyze the various nozzle structures of chip removal systems.By analyzing the influence of the angle of the suction pipe on the velocity field,the combined simulation technology of discrete element and fluid was used to verify the rationality of the suction nozzle structure.A special chip collection device was designed based on the gravity settlement mechanism.Finally,an experimental system was built according to the overall design plan and optimization results of the suction chip removal system.The performance of the chip removal system was studied experimentally from two aspects:the effect of suction chip removal and the surface quality of crystal processing.The experimental result shows that the chip removal system can effectively discharge the chips and improve the proces777sing quality.