Abstract
Slurry concentration and wire speed affect the yield and machining quality of ceramics (Al2O3) that are produced using wire-saw machining (WSM). This study determines the effect of slurry concentration and wire speed on the material removal rate (MRR), the machined surface roughness (SR), the kerf width, the wire wear and the flatness for swinging and non-swinging WSM. The experiments show that swinging WSM results in a higher machining efficiency than non-swinging WSM. WSM with swinging also achieves a peak MRR at a medium slurry concentration (25 wt%) and a higher wire speed (5.6 m/s) using the cutting conditions for the experimental region. However, slurry concentration and wire speed have no significant effect on the machined SR, the kerf width, the wire wear or the flatness for WSM with swinging mode.
Highlights
Precision ceramics are used in a wide range of various advanced applications in the semiconductor and optoelectronics industries
The peak material removal rate (MRR) is achieved at a higher slurry concentration and a higher wire speed
MRR is only achieved by increasing slurry concentration
Summary
Precision ceramics are used in a wide range of various advanced applications in the semiconductor and optoelectronics industries. A wire-saw uses abrasive cutting for the machining of hard, brittle materials and is efficient for cutting ceramics. Yeh et al [8] showed that diamond wear increases as the bonding layer thickness decreases because grains protrude less as the thickness of the electroplated nickel layer increases, especially if the cutting speed and feed rate are increased for wire-sawing of sapphire ingots. Hsu et al [9] used the grey-Taguchi method to optimize the qualities of WSM (MRR, surface roughness, steel wire wear, kerf width and flatness) for ceramics using ultrasonic-assisted vibration. This study determines the effect of machining parameters (slurry concentration, wire speed, swinging frequency and swinging angle) on the machining characteristics (MRR, roughness of the machined surface, kerf width, wire wear and flatness) for WSM with swinging
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