Ultraprecision Ductile-Regime Cutting of Brittle Materials

2007 ◽  
Vol 339 ◽  
pp. 395-399 ◽  
Author(s):  
Ming Zhou ◽  
X.D. Liu ◽  
S.N. Huang
Keyword(s):  
Ultrasonic Vibration ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Diamond Cutting ◽  
Vibration Cutting ◽  
Ductile Regime Machining ◽  
Critical Depth Of Cut ◽  
Micro Deformation ◽  
Micro Indentation

Soda-lime glass is a typical brittle material, which is difficult to realize ductile-regime machining by using conventional cutting technology due to the extremely small critical depth of cut. In this work, the micro-deformation characteristics of this kind of materials were analyzed by micro indentation. Ultrasonic vibration assisted diamond cutting was performed in order to investigate the effect of tool vibration on material removal process and surface quality. The profiles of cut surfaces were measured and compared with those obtained by conventional diamond cutting. Real depths of cut in ultrasonic vibration cutting correspond well with the nominal ones. The change in the tribology of the cutting process as well as the alteration of the deformation mechanism of the work material might be responsible for the reduction in tool wear in vibration cutting.

An Experimental Approach to Determine the Critical Depth of Cut in Brittle-to-Ductile Phase Transition During End Milling of Soda-Lime Glass

2016 ◽  
Vol 41 (11) ◽  
pp. 4553-4562 ◽  
Author(s):  
A. K. M. Nurul Amin ◽  
Mst. Nasima Bagum ◽  
Noor Fathiah ◽  
Mohamed Konneh ◽  
Tasnim Firdaus Bt. Mohamed Ariff
Keyword(s):  
Phase Transition ◽  
Experimental Approach ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Critical Depth ◽  
Ductile Phase ◽  
Critical Depth Of Cut

Single-point diamond machining of glasses

1989 ◽  
Vol 426 (1870) ◽  
pp. 19-30 ◽  
Keyword(s):  
Single Point ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Free Surfaces ◽  
Diamond Machining ◽  
Order Of Magnitude ◽  
Critical Depth Of Cut ◽  
Crucial Part ◽  
Very High

A machine tool of very high stiffness has been constructed and used for single-point diamond grooving of blanks of soda-lime glass and optical glassy quartz. Results show that below a critical depth of cut predicted in order of magnitude by a fracture mechanics analysis, material is removed by the action of plastic flow, leaving crack-free surfaces. Subsequent observations by scanning electron microscopy indicate that a crucial part in the detachment of ribbons of swarf is played by the operation of residual stresses after the passage of the tool, particularly in the case of the amorphous ceramic.

Machining Schemes for Dicing Soda Lime Glass

2010 ◽  
Vol 126-128 ◽  
pp. 263-268
Author(s):  
Jhy Cherng Tsai ◽  
Hong Shin Chen
Keyword(s):  
Front Surface ◽  
Soda Lime ◽  
Fracture Analysis ◽  
Back Surface ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Critical Depth ◽  
Ductile Machining ◽  
One Step ◽  
Critical Depth Of Cut

This research investigates machining schemes for dicing soda lime glass in order to reduce the damage in the processes. Ductile machining and brittle machining of glass are first analyzed based on fracture mechanics and then verified by experiments. Experiments with various machining schemes including scribing-then-breaking, direct-dicing and dicing-then-breaking processes for soda lime glass are then conducted. Experimental observations showed the following results. (i) The critical depth of cut (CDOC) for soda lime glass is between 0.4μm and 0.8μm that matches theoretical prediction, 0.78μm, based on fracture analysis. (ii) The scribing-then-breaking machining scheme results in less damage than the regular slicing process. The DOC of scribing, however, must be in the ductile-brittle region to achieve this result. (iii) Defect due to dicing on the back surface is higher than that on the front surface in one-step dicing through process. Dicing defects can be effectively reduced by decreasing the feed rate or increasing the dicing speed.

Research on the Influence of Cutting Fluids on the Critical Depth of Cut in Diamond Cutting of Optical Glass BK7

2010 ◽  
Vol 431-432 ◽  
pp. 126-129 ◽  
Author(s):  
Ming Zhou ◽  
Peng Jia ◽  
Min Li
Keyword(s):  
Boric Acid ◽  
Optical Glass ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Critical Depth ◽  
Diamond Cutting ◽  
Brittle Ductile Transition ◽  
Fluid Properties ◽  
Critical Depth Of Cut

In diamond cutting of optical glasses, the magnitude of critical depth of cut for brittle-ductile transition is an important factor affecting the machinability of the work material in terms of production rate and surface quality. In this work, scratching tests with increasing depths of cut were conducted on glass BK7 to evaluate the influence of the cutting fluid properties on the critical depth of cut. Boric acid solutions of different concentrations were selected as cutting fluids in the tests. The resulting scratches were examined utilizing a white light interferometer and the values of the critical depth of cut were determined based on the observations of the micro-morphology of the scratch surfaces produced. Experimental results indicated that compared with the process without cutting fluid action, the critical depth of cut in diamond cutting of glass BK7 can be increased by using boric acid solution as the cutting fluid.

Indentation and Scratching Experimental Research on Brittle-Ductile Transition of Optical Glass SF6

2013 ◽  
Vol 589-590 ◽  
pp. 480-484 ◽  
Author(s):  
Peng Jia
Keyword(s):  
Boric Acid ◽  
Optical Glass ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Critical Depth ◽  
Diamond Cutting ◽  
Brittle Ductile Transition ◽  
Fluid Properties ◽  
Critical Depth Of Cut ◽  
Micro Morphology

In diamond cutting of optical glasses, the magnitude of critical depth of cut for brittle-ductile transition is an important factor affecting the machinability of the work material in terms of production rate and surface quality. In this work, scratching tests with increasing depths of cut were conducted on glass BK7 to evaluate the influence of the cutting fluid properties on the critical depth of cut. Boric acid solutions of different concentrations were selected as cutting fluids in the tests. The resulting scratches were examined utilizing a white light interferometer and the values of the critical depth of cut were determined based on the observations of the micro-morphology of the scratch surfaces produced. Experimental results indicated that compared with the process without cutting fluid action, the critical depth of cut in diamond cutting of glass BK7 can be increased by using boric acid solution as the cutting fluid.

Experimental Investigation of the Machinability of Single Crystal Silicon in Laser-Assisted Diamond Cutting

2020 ◽  
Author(s):  
Jinyang Ke ◽  
Xiao Chen ◽  
Jianguo Zhang ◽  
Changlin Liu ◽  
Guoqing Xu ◽  
...  
Keyword(s):  
Single Crystal ◽  
Surface Quality ◽  
Laser Power ◽  
Single Crystal Silicon ◽  
Depth Of Cut ◽  
Maximum Height ◽  
Critical Depth ◽  
Diamond Cutting ◽  
Crystal Silicon ◽  
Critical Depth Of Cut

Abstract Laser-assisted diamond cutting is a promising process for machining hard and brittle materials. A deep knowledge of material removal mechanism and attainable surface integrity are crucial to the development of this new technique. This paper focuses on the application of laser-assisted diamond cutting to single crystal silicon to investigate key characteristics of this process. The influence of laser power on the ductile machinability of single crystal silicon, in terms of the critical depth of cut for ductile-brittle transition in laser-assisted diamond cutting, is investigated quantitatively using a plunge-cut method. The experimental results reveal that this process can enhance the silicon’s ductility and machinability. The critical depth of cut has been increased by up to 330% with laser assistance, and its degree generally increases with the increase of laser power. The cross-sectional transmission electron microscope observation results indicate that laser-assisted diamond cutting is able to realize the subsurface damage free processing of single crystal silicon. In order to verify the ability of the laser-assisted diamond cutting to improve the surface quality, the face turning tests are also carried out. A significant improvement of surface quality has been obtained by laser-assisted diamond cutting: Sz (maximum height) has been reduced by 85% and Sa (arithmetical mean height) has been reduced by 45%.

Numerical Investigation of Two-Dimensional Thermally Assisted Ductile Regime Milling of Brittle Materials

2014 ◽  
Author(s):  
Jianfeng Ma ◽  
Xianchen Ge ◽  
Shuting Lei
Keyword(s):  
Chip Thickness ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Critical Depth ◽  
Uncut Chip Thickness ◽  
Thermal Boundary Conditions ◽  
Orthogonal Machining ◽  
Preheating Temperature ◽  
Ductile Regime Machining ◽  
Critical Depth Of Cut

This study investigates the effects of different variables (preheating temperature, edge radius, and rake angle) on ductile regime milling of a bioceramic material known as nanohydroxyapatite (nano-HAP) using numerical simulation. AdvantEdge FEM Version 6.1 is used to conduct the simulation of 2D milling mimicked by orthogonal machining with varying uncut chip thickness. Thermal boundary conditions are specified to approximate laser preheating of the work material. Based on the pressure-based criterion for ductile regime machining, the dependence of critical depth of cut on cutting conditions is investigated using Tecplot 360. It is found that as uncut chip thickness decreases, the critical depth of cut decreases. In addition, the critical depth of cut increases as the negativity of rake angle and/or preheating temperature increase.

Achievement of Ductile Regime Machining in High Speed End Milling of Soda Lime Glass by Using Tungsten Carbide Tool Insert

2015 ◽  
Vol 1115 ◽  
pp. 39-42
Author(s):  
A.K.M. Nurul Amin ◽  
A.A. Che Omar ◽  
M.A. Mohammed Kamal ◽  
Mahmoud M.A. Nassar ◽  
N.F. Mohd Zaib ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Gas Turbines ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Ductile Regime Machining ◽  
Micro End Milling ◽  
Tungsten Carbide Tool

Soda lime glass is widely used in optics, chemical apparatus, camera lens, micro gas turbines, light bulbs etc. on account of its high hardness, corrosion resistance, and excellent optical properties. These require high dimensional accuracy and flawless surface finish. However, soda lime glass is inherently brittle leading to subsurface crack propagation and fracture which compromise its functionality. To avoid these defects, the machining needs to be performed under ductile mode conditions. Therefore, this research investigates the viability and requisite conditions for achieving ductile regime machining (DRM) in high speed micro-end milling of soda lime glass. Machining was performed at high cutting speeds (30,000 to 50,000 rpm), feed rate (5 to 15 mm/min), and depth of cut (3 to 7 μm). A surface profilometer was then used to measure the surface roughness and a scanning electron microscope (SEM) used to scrutinize the resultant machined surfaces. The results demonstrate that ductile streaks and rounded gummy chips (without sharp or jagged edges) are produced in all runs. In addition, there are no subsurface cracks and the minimum surface roughness attained is 0.08μm. These indicate that DRM of soda lime glass is obtainable using high-speed micro end milling in a conventional end mill with tungsten carbide inserts.

Development of Elliptical Vibration Cutting Technology and its Application to Ultraprecision/Micro Machining of Hard/Brittle Materials

2009 ◽  
Vol 69-70 ◽  
pp. 133-137 ◽  
Author(s):  
Eiji Shamoto ◽  
Norikazu Suzuki
Keyword(s):  
Brittle Materials ◽  
Tungsten Alloy ◽  
Depth Of Cut ◽  
Micro Machining ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Ductile Machining ◽  
Critical Depth Of Cut ◽  
Ultrasonic Elliptical Vibration

Precision machining, named ‘elliptical vibration cutting’, and its application to ultraprecision / micro machining of some hard / brittle materials are introduced in the present paper. The elliptical vibration cutting has a superior cutting performance in terms of low cutting force, low cutting energy, low heat generation, long tool life for steels, sintered tungsten alloy, etc., and large critical depth of cut for ductile machining of brittle materials such as glasses and single crystal calcium fluoride, etc. Based on these basic advantages, practical ultraprecision / micro machining of the hard / brittle materials is successfully realized by employing the ultrasonic elliptical vibration tools, which have been developed for ultraprecision machining.

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