This study proposes a novel ultra-precision machining technology that uses ultrasonic vibration and a straight-nosed diamond tool to improve the processing of the brittle optical material zinc selenide (ZnSe). This research addresses the challenges posed by Poisson's effect in ultrasonic vibration-assisted single-point diamond turning, which causes bending vibration along the depth of cut, resulting in lower machining efficiency and surface quality. This study analyses the relationship between one-dimensional ultrasonic vibrations at the diamond tool edge and induced bending vibrations using both theoretical and experimental methods. By investigating ultrasonic vibration dynamics in the feed direction and at the straight cutting edge, the results showed that ultrasonic vibration helps to improve the ductile-brittle transition ratio of the cutting area and surface quality. These improvements are accomplished by regulating the cutting position at the tool cutting edge, adjusting cutting parameters, and optimizing ultrasonic parameters. The machined surface roughness of ZnSe is reduced by approximately 30–46 % at higher feed rates under ultrasonic vibration with straight-nosed diamond tools. The findings demonstrate the potential of this novel technology to reduce tool wear and brittle fractures, resolving the challenge of ultra-precision machining for optical materials.

中文翻译：

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使用直头金刚石刀具对锌硒化物进行超声波辅助超精密车削


本研究提出了一种新颖的超精密加工技术，该技术利用超声波振动和直头金刚石工具来改善脆性光学材料硒化锌 （ZnSe） 的加工。这项研究解决了泊松效应在超声波振动辅助单点金刚石车削中带来的挑战，该效应会引起沿切削深度的弯曲振动，从而导致加工效率和表面质量降低。本研究使用理论和实验方法分析了金刚石工具边缘的一维超声波振动与诱导弯曲振动之间的关系。通过研究进给方向和直切削刃处的超声振动动力学，结果表明，超声振动有助于提高切削区域的延脆性过渡比和表面质量。这些改进是通过调节刀具切削刃处的切削位置、调整切削参数和优化超声波参数来实现的。使用直头金刚石工具在超声波振动下，在较高的进给速率下，ZnSe 的加工表面粗糙度降低了约 30-46%。研究结果证明了这项新技术在减少刀具磨损和脆性断裂方面的潜力，解决了光学材料超精密加工的挑战。