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.

Effect of Cutter Diameters on Surface Roughness Attained in High Speed End Milling of Soda Lime Glass

2015 ◽  
Vol 1115 ◽  
pp. 51-54 ◽  
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 ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
End Mill ◽  
Machined Surface ◽  
Ductile Mode ◽  
Ductile Regime Machining ◽  
Brittle Fractures

Soda lime glass is used extensively in camera lens, micro gas turbines, light bulbs, tablewares, optics, and chemical apparatus owing to its high hardness, excellent optical properties, and good corrosion and chemical resistance. Such applications of soda lime glass demand high machining and finishing precision. On the other hand, machining of glass poses significant challenges due to its inherent brittleness. The process of removal of material from glass, if not done in ductile mode, can generate subsurface cracks and brittle fractures which have adverse effects on its functionality. This research investigates the high speed micro-end milling of soda lime glass in order to obtain ductile regime machining. It has been found by other researchers that ductile mode machining can avoid sub-surface cracks and brittle fractures. However, in ductile mode machining, the gummy chips settle permanently on the machined surface affecting adversely the surface finish. In order to avoid such chip settlement, compressed air was directed using a special air delivery nozzle to blow away the resultant gummy chips, thereby preventing them from settling on the machined surface. Response surface methodology (RSM) and a commercial NC end mill were used to design and perform the machining runs, respectively. Machining was done using: high spindle speeds from 30,000 to 50,000 rpm, feed rates from 5 to 15 mm/min, and depth of cuts from 3 to 7 μm. Three different diameter carbide tools were used: 0.5, 1, and 2 mm. A surface profilometer was used to analyze the surface roughness of the resultant machined surface. Subsequently, the data was used for finding the best combination of cutting parameters required to obtain the lowest surface roughness. The results demonstrate that high speed machining is a viable option for obtaining ductile regime machining and generating machined surfaces with very low surface roughness in the range of 0.08μm – 0.22 μm, using 0.5 mm carbide end mill cutter.

scholarly journals Optimization of Surface Roughness in Micro-High Speed End Milling of Soda Lime Glass Using Uncoated Tungsten Carbide Tool with Compressed Air Blowing

2014 ◽  
Vol 607 ◽  
pp. 103-107 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Mahmoud M.A. Nassar ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
Brittle Fracture ◽  
High Speed ◽  
End Milling ◽  
Desirability Function ◽  
Soda Lime ◽  
Soda Lime Glass ◽  
Machined Surface ◽  
Air Blowing ◽  
Tungsten Carbide Tool

Soda lime glass is a very important material in diverse manufacturing industries, including automotive, electronics, and aerospace. In these applications, the glass surface needs to be defect free and without impurities. However, the machining of glass is difficult due to its inherent brittleness which leads to brittle fracture and easy crack propagation. This research investigates the high speed micro-end milling of soda lime glass in order to attain ductile regime machining. It has been found by other researchers that ductile mode machining can avoid brittle fracture and sub-surface cracks. Also, in this study, a special air delivery nozzle is used to blow away the resultant chips and keep the machined surface clean. To accomplish this, Design Expert software and a commercial NC end mill were used to design and perform the machining runs, respectively. The surface roughness of the resultant surfaces was later analyzed with a surface profilometer. Microphotographs of the machined surfaces were also taken in order to see how effective the air blowing method is. The results of surface roughness measurements were then used to develop a quadratic empirical model for surface finish prediction. Finally, desirability function and genetic algorithms were used to predict the best combination of cutting parameters needed to obtain the lowest surface roughness. The predictions were later tested by experiments. The results demonstrate that this type of machining is viable and the roughness obtained is very low at 0.049 μm.

Surface Roughness Model for High Speed End Milling of Soda Lime Glass Using Carbide Coated Tools with Compressed Air Blowing

2012 ◽  
Vol 576 ◽  
pp. 107-110
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
Muammer Din Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Gas Turbines ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Machining Parameters ◽  
Machined Surface

Glass materials play a vital role in advancement of science and technology. They have found wide spread application in the industry, in laboratory equipment and in micro-gas turbines. Due to their low fracture toughness they are very difficult to machine, moreover there are the chip depositions on the machined surface which affects surface finish under ductile mode cutting conditions. In this research, high speed end milling of soda lime glass is performed on CNC vertical milling machine to investigate the effects of machining parameters i.e. spindle speed, depth of cut, and feed rate on machined surface roughness. Design of experiments was performed following Central Composite Design (CCD) of Response Surface Methodology (RSM). Design Expert Software was used for generating the empirical mathematical model for average surface roughness. The model’s validity was tested to 95% confidence level by Analysis of Variance (ANOVA). Subsequent experimental results showed that the developed mathematical model could successfully describe the performance indicators, i.e. surface roughness, within the controlled limits of the factors that were considered.

Optimization of Cutting Parameters in High Speed End Milling of Soda Lime Glass with Coated Carbide Tools Using Directional Compressed Air Blowing

2012 ◽  
Vol 576 ◽  
pp. 111-114
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Compressed Air ◽  
Soda Lime Glass ◽  
Machining Parameters ◽  
Design Expert ◽  
Air Blowing ◽  
Optimization Of Cutting Parameters

An experimental study of high speed machining of soda lime glass using directional compressed air blowing for removal of the ductile chips from the machined surface, is presented. High speed end milling of soda lime glass is performed on a vertical CNC milling machine to observe the effects of machining parameters i.e. spindle speed, depth of cut and feed rate on the resultant surface roughness. The design of the experiments was performed following the Central Composite Design (CCD) of the Response Surface methodology (RSM) using the Design Expert Software. Optimization of machining parameters was conducted using desirability function of the Design Expert software based on minimum surface roughness criterion. Finally, experimental verification tests were conducted to validate the predicted optimized value.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

scholarly journals Machinability of Soda Lime Glass in High Speed End Milling

2018 ◽  
Vol 290 ◽  
pp. 012036
Author(s):  
Mohamed Konneh ◽  
Mst. Nasima Bagum ◽  
Tasnim Firdaus Bt. Mohamed Arif ◽  
Mohammad Yeakub Ali
Keyword(s):  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Soda Lime Glass

Experimental Investigation and Estimation of Surface Roughness using ANN, GMDH & MRA models in High Speed Micro End Milling of Titanium Alloy (Grade-5)

2017 ◽  
Vol 4 (2) ◽  
pp. 1019-1028 ◽  
Author(s):  
Chakradhar Bandapalli ◽  
Bharatkumar Mohanbhai Sutaria ◽  
Dhananjay Vishnuprasad Bhatt ◽  
Kundan Kumar Singh
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Titanium Alloy ◽  
High Speed ◽  
End Milling ◽  
Grade 5 ◽  
Micro End Milling

Investigation of Heat Assisted High Speed End Milling of Soda Lime Glass for Surface Generation

2017 ◽  
Vol 740 ◽  
pp. 145-151
Author(s):  
Mohamed Konneh ◽  
Mst. Nasima Bagum ◽  
A.K.M. Nurul Amin ◽  
Amira Fatin Asyah
Keyword(s):  
Surface Finish ◽  
Feed Rate ◽  
High Speed ◽  
End Milling ◽  
Heating Temperature ◽  
Soda Lime ◽  
Surface Generation ◽  
Quadratic Model ◽  
Depth Of Cut ◽  
Soda Lime Glass

Brittle materials like soda lime glass can be machined in ductile mode under controlled machining conditions (feed rate, depth of cut, small tool edge radius) using high speed to generate a desired surface finish. The heat generated in high speed machining tends to promote ductile machining. In this paper, heat assisted high speed end milling is investigated to explore machinability of the soda lime glass. The heat assisted machining thus generates low surface finish on the machined workpiece. The heat assisted high speed end milling of soda lime was carried out using uncoated 2 flute carbide end mill at a constant depth of cut 25 μm, while the spindle speed and feed rate were varied from 30,000 to 50,000 rpm and 45 to 75 mm/min, respectively. The applied temperature was varied from 200 °C to 300 °C. The observations of machined surface were done on Surf-test (SV-514) and Scanning Electron microscope (SEM). A quadratic model for roughness (Ra) was developed using Central Composite Design of experiment. The optimum Ra, 0.10 μm was achieved at 49,570 rpm, 58 mm/min feed rate and heating temperature at 238°C. It is found that cutting speed has the greatest influence on the surface roughness value, followed by feed rate and heating temperature.

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