Abstract
Glass is a hard and brittle material. It is finding mounting quantum of applications in semiconductor, opto-electronics, and mold manufacturing sectors. However, glass is not amenable to machining because of its low fracture toughness. If machined with conventional approach, the mechanism of material removal in machining of glass is fracture based that results into poor quality of the machined surface and imparts subsurface damage. In order to achieve superior surface finish, glass must be machined in ductile mode. Ductile-mode machining is now a well-established technique but most of the work has been performed with single-point cutting processes. To assess the capability of ductile-mode machining with multipoint cutting process, fundamental studies are highly desired. This paper reports the results of an experimental investigation into ductile-mode machining of glass by milling process. Side-milling tests have been performed on the glass workpiece to identify the key parameters governing the ductile-brittle transition mechanism. Experimental results demonstrate that fracture-free surface can be machined on glass by milling process. Cutting forces were analyzed to comprehend the dynamic behavior of the cutting process in ductile mode.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Zhou M, Ngoi BKA, Yusoff MN, Wang XJ (2006) Tool wear and surface finish in diamond cutting of optical glass. J Mater Process Technol 174:29–33
Namba Y, Abe M (1993) Ultraprecision grinding of optical glasses to produce super-smooth surfaces. Ann CIRP 42(1):417–420
Foy K, ZhiWei TM, Huang Y (2009) Effect of tilt angle on cutting regime transition in glass micromilling. Int J Mach Tools Manuf 49:315–332
Jong de BHWS (1989) Glass. In: Ullmann’s Encyclopedia of Industrial Chemistry, 5th edn. VCH Publishers, Weinheim, Germany, vol. A12. pp.365–432
Fang FZ, Chen LJ (2000) Ultra-precision cutting for ZKN7 glass. Ann ClRP 49(1):17–20
Liu K, Zuo D, Li XP, Rahman M (2009) Nanometric ductile cutting characteristics of silicon wafer using single crystal diamond tools. J Vacuum Sci Technol 27(3):1361–1366
Marshall DB, Lawn BR (1986) Indentation of brittle materials. In: Blau PJ, Lawn BR (eds) Microindentation techniques in materials science and engineering. American Society for testing and materials, Philadelphia, pp 26–46
Brehm R, Dun V, Teuunissen K, Haisma CG (1979) Transparent single-point turning of optical glass. J Precision Eng 1(3):207–213
Blackley WS, Scattergood RO (1991) Ductilc regime model for diamond turning of brittle materials. J Precision Eng 13(2):95–102
Gee AE, Spragg RC, Puttick KE, Rudman MR (1991) Single-point diamond form-finishing of glasses and other macroscopically brittle materials. Proc SPIE 1573:39–48
Moriwaki T, Shamato E, Inoue K (1992) Ultraprecision ductile cutting of glass by applying ultrasonic vibration. Ann CIRP 41:141–144
Komanduri R (1996) On material removal mechanisms in finishing of advance ceramics and glasses. Ann CIRP 45:509–513
Patten J, Gao W, Yasuto K (2005) Ductile regime nanomachining of single-crystal silicon carbide. Trans ASME 127:522–532
Yoshino M, Ogawa Y, Aravindan S (2005) Machining of hard-brittle materials by a single point tool under external hydrostatic pressure. J Manuf Sci Eng 127(4):837–845
Liu K, Li X, Liang SY, Liu XD (2004) Nanometer scale ductile mode cutting of soda- lime glass. Trans NAMRI/SME 32:39–45
Patten J, Gao W, Yasuto K (2005) Ductile regime nanomachining of single-crystal silicon carbide. J Manuf Sci Eng 127:522–532
Cai MB, Li XP, Rahman M (2007) Study of the mechanism of nanoscale ductile mode cutting of silicon using molecular dynamic simulation. Int J Mach Tools Manuf 47:75–80
Sreejith PS, Ngoi BKA (2001) Material removal mechanism in precision machining of new materials. Int J Mach Tools Manuf 41:1831–1843
Fang FZ, Zhang GX (2004) An experimental study of optical glass machining. Int J Adv Manuf Technol 23:155–160
Jared BH, Dow TA (1997) Chip dynamics in diamond turning. Proc ASPE 16:230–233
Shimada S, Ikawa N, Inamura T, Takezawa N, Ohmori H, Sata T (1995) Brittle-ductile transition phenomena in microindentation and micromachining. Ann CIRP 44(1):523–526
Lucca DA, Brinksmeier E, Goch G (1998) Process in assessing surface and subsurface integrity. Ann CIRP 47(12):669–694
Stavropoulos P, Salonitis A, Stournaras A, Pandremenos J, Paralikas J, Chryssolouris G (2007) Advances and challenges for tool condition monitoring in micro-milling. In: Proceeding of the IFAC workshop on manufacturing, management and control, Budapest, Hungry. pp. 157–162
Stavropoulos P, Salonitis A, Stournaras A, Pandremenos J, Paralikas J, Chryssolouris G (2007) Tool condition monitoring in micro-milling—a critical review. Advances in manufacturing technology XXI. In: Proceedings of the 5th international conference on manufacturing research, Leicester, UK. pp. 324–328
Stavropoulos P, Stournaras A, Chryssolouris G (2009) On the design of a monitoring system for desktop micromilling machines. Int J Nanomanuf 3(1/2):29–39
Takeuchi Y, Sawada K, Sata T (1996) Ultraprecision 3D micromachining of glass. Ann CIRP 45(1):401–404
Matsumura T, Ono T (2005) Glass machining with ball end mill. Trans NAMRI/SME 33:319–326
Matsumura T, Hiramatsu T, Shirakashi T, Muramatsu T (2005) A study on cutting force in the milling process of glass. J Manuf Processes 7(2):102–108
Matsumura T, Ono T (2008) Cutting process of glass with inclined ball end mill. J Mater Process Technol 200:356–363
Ono T, Takashi M (2008) Influence of tool inclination on brittle fracture in glass cutting with ball end mills. Int J Mater Process Technol 202:61–69
Kim C-J, Mayor JR, Ni J (2004) A static model of chip formation in microscale milling. Trans ASME J Manuf Sci Eng 126:710–718
Chae J, Park SS, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46:313–332
Basuray PK, Misra BK, Lal GK (1977) Transition from ploughing to cutting during machining with blunt tools. Wear 43:341–349
Chiu WC, Endres WJ, Thouless MD (2000) An experimental study of orthogonal machining of glass. Mach Sci Technol 4(2):253–275
Chiu WC, Endres WJ, Thouless MD (2001) An analysis of surface cracking during orthogonal machining of glass. Mach Sci Technol 5(2):195–215
Sreejith P (2005) Machining force studies on ductile machining of silicon nitride. J Mater Process Technol 169(3):414–417
Rusnaldy Ko TJ, Kim HS (2007) An experimental study on microcutting of silicon using a micromilling machine. Int J Adv Manuf Technol 39(1–2):85–91
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Arif, M., Rahman, M., San, W.Y. et al. An experimental approach to study the capability of end-milling for microcutting of glass. Int J Adv Manuf Technol 53, 1063–1073 (2011). https://doi.org/10.1007/s00170-010-2893-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-010-2893-y