Intermittent and Continuous Rotary Ultrasonic Machining of K9 Glass: An Experimental Investigation

Palamandadige Fernando,Meng Zhang,Zhijian Pei,Weilong Cong

doi:10.3390/jmmp1020020

Abstract

Rotary ultrasonic machining (RUM) is a nontraditional and cost-effective machining method for hard and brittle materials, such as ceramics, optical glass, composite materials, and so on. RUM is a hybrid process that combines the material removal mechanisms of diamond abrasive grinding and ultrasonic machining. In RUM, a rotating cutting tool with metal-bonded diamond abrasive particles is ultrasonically vibrated in the axial direction while the tool spindle is fed toward the workpiece at a constant feedrate to remove material. It has been reported that continuous rotary ultrasonic machining has been successfully used to drill holes in K9 glass. Intermittent rotary ultrasonic machining is a newly introduced ultrasonic machining process, which uses a slotted cutting tool instead of a common metal bonded diamond cutting tool as used in continuous rotary ultrasonic machining. There has been no reported study to compare the effects of intermittent RUM and continuous RUM when machining K9 glass. This paper, for the first time, presents an experimental investigation to compare intermittent RUM and continuous RUM when machining K9 glass from the perspectives of cutting force, surface roughness, and chipping size.

Highlights

Park et al investigated micro machining of K9 glass by using micro-abrasives, which were accelerated by compressed air to form linear grooves and holes with width and diameter of 80 μm [5]
Matsumura et al reported the use of abrasive water jet to make grooves of 20–100 μm wide on glass [6]
Zeng et al did an experimental investigation on intermittent rotary ultrasonic machining of alumina (92% hot-pressed) [18]

Summary

Introduction

K9 glass is regarded as a difficult-to-machine material due to its mechanical properties, such as high hardness, high strength, and low fracture toughness [3]. Other material properties that give K9 glass a broad application include its low density, high thermal resistance, and good resistance to corrosion and wear. Some material processing techniques have been reported on machining of K9 glass. Rotary ultrasonic machining (RUM) has been applied to K9 glass machining [3,7,8,9].

Results

Conclusion