An experimental approach to determine the critical depth of cut in brittle-to-ductile phase transition during end milling of soda lime glass

Amin, A. K. M. Nurul and Begum, Mst. Nasima and Fathiah, Noor and Konneh, Mohamed and Ariff, Tasnim Firdaus (2016) An experimental approach to determine the critical depth of cut in brittle-to-ductile phase transition during end milling of soda lime glass. Arabian Journal for Science and Engineering, 41 (11). pp. 4553-4562. ISSN 1319-8025 E-ISSN 2191-4281

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Abstract

Plastic deformation is a predominant material removal mechanism in machining of ductile materials, but it is a big challenge to achieve it in cases of brittle materials. Soda-lime glass is a very useful engineering material. Due to its favorable thermal, corrosion resistance and fine chemical properties, its common applications are in the manufacture of products like mirrors, lenses, semiconductor, and optical, bio-medical and microelectronics components. Nevertheless, owing to its brittleness due to its low fracture toughness, machining of soda-lime glass is practically impossible under normal cutting conditions. Though recent investigations have shown that machining of such brittle material is possible using ductile mode machining under controlled cutting parameters and tool geometry, it remains a challenging task. This paper focuses on identification of the critical axial depth of cut under specific feed per tooth and cutting speed in high-speed end milling of soda-lime glass. A two-fluted solid end mill of 4 mm diameter was used with cutting speed ranging from 377 to 628 m/min and feed rate from 5 to 20 mm/min to investigate the phenomenon of transition from plowing to ductile and ductile to brittle machining mode. The work piece was placed at a specific angle to facilitate machining at gradual increment in depths for different feed rates and cutting speeds combinations. At the highest available cutting speed, three phases (plowing, ductile, and brittle) were observed at a specific feed rate, resulting in a critical depth of cut 51.943 μμm and chip thickness approximately 198 nm.

Item Type:	Article (Journal)
Additional Information:	5202/51080
Uncontrolled Keywords:	Ductile regime machining high-speed machining, soda-lime glass, phase transition, critical depth of cut
Subjects:	T Technology > T Technology (General) > T175 Industrial research. Research and development T Technology > TP Chemical technology > TP785 Clay industries. Ceramics. Glass. Cement industries
Kulliyyahs/Centres/Divisions/Institutes (Can select more than one option. Press CONTROL button):	Kulliyyah of Engineering > Department of Manufacturing and Materials Engineering
Depositing User:	Dr. Tasnim Firdaus Ariff
Date Deposited:	13 Jul 2016 06:34
Last Modified:	13 Jan 2017 16:44
URI:	http://irep.iium.edu.my/id/eprint/51080

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