Machining of hard and brittle materials: A comprehensive review

Sharma, Ankit; Kalsia, Mohit; Uppal, Amrinder Singh; Babbar, Atul; Dhawan, Vikas

doi:10.1016/j.matpr.2021.07.452

Cited by 20 publications

(7 citation statements)

References 29 publications

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“…Recently, the demand for hard and brittle materials, including Zirconia (ZrO 2 ) and BK7 glass, has increased significantly, capturing heightened attention [1][2][3]. This interest is attributed to their desirable mechanical properties, such as their high bending strength, metallic luster, effective conductivity, elevated hardness, robust corrosion resistance, substantial modulus of elasticity, superior resistance to crack propagation, and minimal thermal expansion [4,5].…”

Section: Introductionmentioning

confidence: 99%

Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

Manea,

Lu,

Liu

et al. 2024

Mathematics

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This article explores the intricacies of micro-grinding parameter control for hard and brittle materials, with a specific focus on Zirconia ceramics (ZrO2) and Optical Glass (BK7). Given the increasing demand and application of these materials in various high-precision industries, this study aims to provide a comprehensive kinematic analysis of material removal during the micro-grinding process. According to the grinding parameters selected to be analyzed in this study, the ac-max values are between (9.55 nm ~ 67.58 nm). Theoretical modeling of the grinding force considering the brittle and ductile removal phase, frictional effects, the possibility of grit to cut materials, and grinding conditions is very important in order to control and optimize the surface grinding process. This research introduces novel models for predicting and optimizing micro-grinding forces effectively. The primary objective is to establish a micro-grinding force model that facilitates the easy manipulation of micro-grinding parameters, thereby optimizing the machining process for these challenging materials. Through experimental investigations conducted on Zirconia ceramics, the paper evaluates a mathematical model of the grinding force, highlighting its significance in predicting and controlling the forces involved in micro-grinding. The suggested model underwent thorough testing to assess its validity, revealing an accuracy with average variances of 6.616% for the normal force and 5.752% for the tangential force. Additionally, the study delves into the coefficient of friction within the grinding process, suggesting a novel frictional force model. This model is assessed through a series of experiments on Optical Glass BK7, aiming to accurately characterize the frictional forces at play during grinding. The empirical results obtained from both sets of experiments—on Zirconia ceramics and Optical Glass BK7—substantiate the efficacy of the proposed models. These findings confirm the models’ capability to accurately describe the force dynamics in the micro-grinding of hard and brittle materials. The research not only contributes to the theoretical understanding of micro-grinding processes but also offers practical insights for enhancing the efficiency and effectiveness of machining operations involving hard and brittle materials.

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Section: Introductionmentioning

confidence: 99%

Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

Manea,

Lu,

Liu

et al. 2024

Mathematics

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“…Recently, the demand for finishing hardened materials along with the requirements for productivity as well as ensuring environmental friendliness has been increasing to put more pressure on finding out the novel technological solutions. 1 The traditional method for finishing heat-treated steels is the grinding process. Low productivity and the problem of environmental pollution from the use of coolant are still inherent disadvantages, so hard machining technology was researched and developed in the 1980s.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Al₂O₃ nanoparticle concentration and cutting parameters in hard milling under nanofluid MQL environment

Duc,

Tuan,

Long

2024

Advances in Mechanical Engineering

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The high cutting heat and cutting forces are still the big obstacles in hard machining technology, which puts more pressure to find out the alternative solution for these problems. The work content presents an experimental study on the effect of nanoparticle concentration and cutting parameters on surface roughness and cutting force during hard milling under MQL environment using Al2O3 nano-cutting oil. The Box-Behnken experimental designs for response surface methodology was used to evaluate the influence of the input parameters and determine the optimal values. The obtained results show that the nanoparticle concentration, cutting speed, and feed rate all have the great influences on surface roughness R z and resultant cutting force F, so the study of the influence of these parameters on the efficiency of the hard milling process is very significant. The proposed reasonable value ranges will help technicians quickly choose to meet their demands for specific objective functions. Furthermore, the optimal parameter set of nanoparticle concentration of 1.27 wt%, cutting speed V c = 103 m/min, and feed rate [Formula: see text] = 0.09 mm/tooth was determined. It revealed that the use of MQL with nano-cutting oils contributed to improve the lubrication and cooling performance in the cutting zone.

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“…Nonmetallic hard-brittle materials, such as ceramic materials, exhibit high hardness, high strength, corrosion resistance, low density, and high chemical stability, thus making them ideal candidates to be used in high-tech industries such as precision instruments, aerospace, and biomedical engineering. [1,2] However, because of their high brittleness, high hardness, low fracture toughness, and low plasticity, they are considered typical difficult-to-machine materials. The high difficulty to machine ceramic materials leads to the rapid wear and failure of the cutting tools, in conjunction with damage to the surface quality of the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Cutting Performance and Wear Mechanism of Multilayer Diamond‐Coated Tools

et al. 2023

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Monolayer and multilayer diamond films are deposited on WC‐Co cemented carbide by hot‐filament chemical vapor deposition. The growth characteristics of diamond coatings are analyzed. Cutting performance characteristics such as tool life and the stability of machining process in the machining of presintered ZrO2 are compared based on the variation of cutting speed and resultant cutting force, and workpiece surface roughness. For the monolayer diamond coatings, as the concentration of CH4 increases from 1% to 5%, the diamond crystal is transformed from micron columnar crystal to nanocluster crystal. The multilayer diamond coatings combine the advantages of micron‐ and nanocrystalline structures. The multilayer diamond‐coated tool exhibits longer service life and better machining quality. Because of the appearance of the brittle–plastic conversion mechanism, the surface integrity of ZrO2 processed by multilayer diamond‐coated tool is relatively high. As for the uncoated tool, the workpiece is mainly machined by brittle spalling. The interfacial stratified fracture system between the interlayers is proposed to be the toughening mechanism of the multilayer structure.

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Machining of hard and brittle materials: A comprehensive review

Cited by 20 publications

References 29 publications

Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

Optimization of Al₂O₃ nanoparticle concentration and cutting parameters in hard milling under nanofluid MQL environment

Cutting Performance and Wear Mechanism of Multilayer Diamond‐Coated Tools

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Machining of hard and brittle materials: A comprehensive review

Cited by 20 publications

References 29 publications

Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

Optimization of Al2O3 nanoparticle concentration and cutting parameters in hard milling under nanofluid MQL environment

Cutting Performance and Wear Mechanism of Multilayer Diamond‐Coated Tools

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Optimization of Al₂O₃ nanoparticle concentration and cutting parameters in hard milling under nanofluid MQL environment