Application analysis of customized Zerodur machining in gyroscope parts

Application analysis of customized Zerodur machining in gyroscope parts

Zerodur, a special glass ceramic material, is known for its near zero coefficient of thermal expansion, excellent dimensional stability, and extremely strong environmental adaptability. With these unique characteristics, Zerodur has become an indispensable key material in high-precision devices, especially in the manufacturing of gyroscope components in the aerospace, navigation, and defense fields. This article will delve into the characteristics of Zerodur material and its application in the machining of gyroscope parts, analyzing the challenges and solutions faced during the machining process

What is Zerodur? Why is it suitable for gyroscope components?

The unique features of Zerodur

Zerodur is a high-performance glass ceramic material developed by the German company SCHOTT. Its main components are silicon dioxide and aluminum oxide, and its thermal expansion characteristics are controlled by precise proportioning of trace elements. The following are the core advantages of Zerodur:

Near zero coefficient of thermal expansion: Temperature changes have minimal impact on size, ensuring stable performance of the equipment under various temperature conditions.

Excellent dimensional stability: There is almost no dimensional drift during long-term use, making it very suitable for high-precision environments.

Chemical corrosion resistance: Even in harsh environments, materials can remain stable and are not easily affected by corrosion or reactions.

High strength and rigidity: able to withstand mechanical pressure without deformation, suitable for structural design of complex parts.

Why do gyroscopes need Zerodur

A gyroscope is a precision instrument used to measure angular velocity and attitude. In aerospace, satellite navigation, and submarine guidance systems, the core components of gyroscopes require extremely high precision and stability. The unique features of Zerodur perfectly meet these demanding requirements.

Common applications include:

Optical reflector: used in laser gyroscopes to reflect light beams and ensure stable optical paths.

Supporting structure: provides strong support for sensitive components while maintaining precise alignment.

Rotor casing: protects high-speed rotating components and maintains structural integrity.

The Challenge of Zerodur Processing

Although Zerodur has superior performance, its hardness and brittleness pose significant challenges to machining. Traditional processing methods are difficult to meet the requirements, and advanced technology is needed to achieve high-precision manufacturing.

1. Brittle problem

Zerodur is prone to micro cracks and even collapse during the machining process, so it is necessary to choose appropriate tools and machining parameters to minimize damage.

2. Hardness issue

The Mohs hardness of Zerodur is 5.5, which means that high hardness tools such as diamond cutting tools are required for processing, otherwise it is difficult to meet the requirements of precision machining.

3. Thermal sensitivity

Although the thermal expansion coefficient of Zerodur itself is close to zero, the high temperature generated during the processing may affect accuracy. Therefore, effective cooling techniques need to be used to control the temperature in the processing area.

The practical application of Zerodur in gyroscope

1. Ring Laser Gyroscope (RLG)

The mirrors and shells made of Zerodur greatly enhance the stability and measurement accuracy of laser navigation systems.

2. Fiber Optic Gyroscope (FOG)

The support structure uses Zerodur to reduce errors caused by temperature fluctuations in fiber optic components, ensuring stability during long-term operation.

3. Mechanical gyroscope

Zerodur's rotor and stator components maintain consistent performance in high stress environments, making them particularly suitable for precision equipment that rotates at high speeds.

Zerodur machining quality control

Quality control runs through the entire manufacturing process of gyroscope components to ensure that each product meets high standard technical requirements.

1. Dimensional inspection

Use a coordinate measuring machine (CMM) to verify the critical dimensions of the parts and ensure that the error is controlled at the micrometer level.

2. Surface roughness detection

Measure surface smoothness using tools such as interferometers to ensure compliance with optical or mechanical connection requirements.

3. Stress testing

Detecting potential cracks inside parts through ultrasound or X-ray to ensure their long-term reliability for use

Zerodur is an ideal choice for gyroscope core components due to its excellent thermal stability and mechanical properties. However, its processing requires profound technical accumulation and specialized equipment, and only a professional team can fully tap into its material potential to provide reliable guarantees for high-precision equipment. In the future, with the continuous breakthroughs in processing technology, the application prospects of Zerodur will be even broader.

If you are looking for reliable Zerodur machining services, choosing an experienced and professional team is the best way to ensure quality and efficiency.

Jundro Ceramics has rich experience in this field. You can contact our experts, and we are happy to provide you with professional services