Alumina ceramic precision cutting skills detailed

The effective methods for cutting alumina ceramics include laser cutting, drilling and grinding and ultrasonic cutting. Among them, laser cutting has high precision and high efficiency, which is suitable for high-precision machining; Ultrasonic cutting rule has the characteristics of environmental protection and smooth cutting surface, which is suitable for cutting large alumina ceramics; The drilling and grinding rule is suitable for cost-sensitive applications.

Physical properties of alumina ceramics

Alumina ceramic is a kind of high temperature ceramic, with high hardness, high strength, wear resistance, corrosion resistance and other properties. However, because alumina ceramics are too hard and brittle, it is difficult to achieve traditional mechanical cutting, so other cutting methods are needed.

Common cutting method of alumina ceramics

1. Laser cutting

Laser cutting is suitable for aluminum oxide ceramic sheet material, with high precision, non-contact cutting, less cutting residue and other advantages, but the equipment is expensive, applicability is not wide enough. Laser processing is a kind of processing method that uses high energy laser beam to cut, punch and surface treatment materials. In the laser processing of alumina ceramics, the high energy of the laser beam can make the alumina ceramics melt or vaporize rapidly, so as to achieve the removal of the material. Laser processing has the advantages of non-contact, non-pollution and high precision, which is suitable for processing complex shapes of workpieces.

2. Drilling and grinding method

The method is used to drill holes on alumina ceramics and trim with diamond grinding head at the drilling place. It is suitable for the processing of a single small piece, but it has high technological requirements and limited application range.

3. Ultrasonic cutting method

Ultrasonic cutting method uses the high energy shock wave of ultrasonic waves to separate objects, which is suitable for the cutting of hard and brittle materials such as alumina ceramics, and can accurately cut out complex shapes with high cutting surface finish. Ultrasonic machining is a kind of machining method that uses ultrasonic vibration to cut, punch and grind materials. In the ultrasonic processing of alumina ceramics, the energy of ultrasonic vibration can make the alumina ceramics plastic deformation, so as to achieve the removal of materials. Ultrasonic machining is suitable for machining thin walls and complex shapes of the workpiece.

In addition to the above three common cutting methods, there are some other methods, such as plasma cutting, electric spark cutting and so on. Different cutting methods have advantages and disadvantages, and it is necessary to choose the appropriate cutting method according to the specific processing needs.

We use laser cutting alumina ceramics as an example

Laser cutting alumina ceramic cutting precautions

1. Select the appropriate cutting tools and methods to ensure the flatness and finish of the cutting surface.

2. In the cutting process, it is necessary to use coolant to cool down and prevent the deformation of the ceramic at high temperature.

3. Before cutting, it is necessary to carry out manual spraying, mold making and other processes according to the needs to ensure the smoothness of the ceramic surface.

4. It is necessary to grind and polish the cutting surface after cutting to ensure that the finish of the cutting surface meets the standard.

5. Due to the high hardness of alumina ceramics, the pressure and speed need to be properly controlled during the cutting process to avoid fragmentation.

Principle of laser cutting

Laser cutting is the use of a focused high-power density laser beam to irradiate the workpiece, so that the irradiated material quickly melted, vaporized, ablated or reached the ignition point, and at the same time with the beam coaxial high-speed airflow to blow off the molten material, so as to achieve the workpiece cut. Laser cutting is one of the thermal cutting methods.

Classification of laser cutting

1) Gasification cutting

Laser gasification cutting is mostly used for cutting extremely thin metal materials and non-metallic materials (such as paper, cloth, wood, plastic and rubber, etc.).

2) Melting and cutting

Laser melting cutting is mainly used for the cutting of some non-oxidizing materials or active metals, such as stainless steel, titanium, aluminum and its alloys.

3) Oxygen cutting

Laser oxygen cutting is mainly used for carbon steel, titanium steel and heat-treated steel and other easily oxidized metal materials.

4) Scribing and controlling fracture

Laser scribing is the use of high energy density laser scanning on the surface of the brittle material, so that the material is heated to evaporate out of a small slot, and then apply a certain pressure, the brittle material will be split along the small slot. The lasers used for laser scribing are generally Q-switched lasers and CO2 lasers.

Controlled fracture is the use of the steep temperature distribution generated by laser grooving to create local thermal stress in the brittle material, causing the material to break along the small grooves.

Precautions when cutting

Because of the high hardness and brittleness of alumina ceramic material, it is easy to collapse. When cutting, the following points should be noted:

Selection of adhesive film: Select a film with thin adhesive layer and strong adhesion for fixation.

Cooling water: The cutting process generates high temperatures. Pay attention to adjust the cooling water flow and Angle.

Blade maintenance: The new blade needs to be repaired in time during the machine and cutting process to ensure the sharpness of the blade and avoid the product collapse caused by insufficient cutting force of the blade.

Cutting speed: The cutting speed is generally set at 5-8mm/s, and too much material is easy to cause edge breakage.

Electroplating soft knife, metal soft knife, resin soft knife can be selected to cut alumina ceramic substrate according to different requirements.

Equipment workflow

1. Remove the material to be cut from the chip box by the lower arm, place the material to be cut on the pre-calibration table for pre-calibration, and then send it to the work plate for scribing.

2. The upper lifting arm moves the cut material from the work plate to the cleaning plate for two-fluid cleaning and wafer drying.

3. Put the cut material back into the pre-calibration table for pre-calibration, and then push it back into the chip box.

Alumina ceramic is a kind of high hardness, high strength material, traditional mechanical cutting is difficult to achieve, need to use laser cutting, drilling and grinding method, ultrasonic cutting method and other special methods, cutting need to pay attention to matters, such as choosing the right cutting tools and methods, coolant cooling, etc., in order to accurately cut high-quality alumina ceramic products.