A Multiphysics simulation study of the influence of adhesive layer thickness on the laser optical response of diamond scratching tools

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Abstract
This study addresses the issue of adhesive wear in diamond tools during laser in-situ assisted mechanical scratching. Based on Multiphysics simulation, it reveals the mechanisms by which different adhesive layer thicknesses affect the laser field distribution, intensity distribution, and propagation characteristics of the tool. During the laser-assisted scratching process, workpiece material tends to adhere to the tool surface and form adhesive layers with different thicknesses, and the adhesive layer thickness can be regarded as an important state parameter for characterizing the progression of adhesive wear. Based on COMSOL Multiphysics, tool models with different adhesive layer thicknesses were established, and coupled analyses of heat transfer, wave optics, and ray optics were systematically carried out. The results show that laser transmission through the tool induces significant temperature field evolution and thermal deformation, and the thermal load has an important effect on the structural integrity of the tool. After the laser enters the transparent diamond scratching tool, it is jointly affected by the tool geometry and the optical properties of the adhesive layer interface. Reflection, refraction, and interference occur inside the tool and near its surface, resulting in a non-uniform optical field distribution characterized by alternating localized enhancement and attenuation in space. The presence of an adhesive layer leads to asymmetric electric field distribution, enhanced local field intensity, and more complex processes of reflection, refraction, and scattering on the tool surface. With increasing adhesive layer thickness, the propagation paths of rays inside the tool become progressively disordered, energy dispersion is intensified, and the transmitted laser power density decreases significantly. This paper reveals the intrinsic relationship between the thickness of the adhesive layer and the distribution and propagation characteristics of the laser light field from the perspective of Multiphysics simulation, providing a theoretical basis and simulation foundation for characterizing the adhesive wear state of diamond scratching tools based on light intensity distribution and propagation response characteristics.
Funding Information
  • Natural Science Foundation of Jilin Province (20240101078JC)
  • Scientific Research Project of Jilin Provincial Department of Education (JJKH20230809KJ)
  • National Natural Science Foundation of China (52375405)
  • Lu Quan Innovation Fund

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