Micro machining glass with polycrystalline diamond tools shaped by micro electro discharge machining

Morgan, Chris; Vallance, R. Ryan; Marsh, Eric Russell

doi:10.1088/0960-1317/14/12/013

Cited by 116 publications

(48 citation statements)

References 11 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…How to increase eroding speed, reduce the wear of electrode and maintain reasonable accuracy at the same time has always been the topic of EDM [11][12][13][14][15][16]. As for fabricating PCD tools, the aforementioned studies mainly focus on the methods of using the Sinker EDM and the Wire EDM [12,14,[17][18][19][20][21][22][23][24][25]. Few researches on the EDM mechanism of special-edge diamond tools, especially with disk erosion, have been reported to the authors' best knowledge.…”

Section: Introductionmentioning

confidence: 99%

Edge fabrication and process optimization of precision woodworking PCD millers with disk electrical discharge machining

Zhang

et al. 2015

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Polycrystalline diamond (PCD) tools fulfil a vital role in the woodworking industry, with its ability to achieve smooth machining quality and long service life, along with excellent performance features. However, diamond tools' fabrication is a difficult material removal process. In this study, we propose and develop an electrical discharge machining (EDM) grinding method with disk electrode. Tool profiles are captured by a measuring probe, and path curves are tracked by a peripheral disk in edge fabrication. Experiments of graphite and copper serving as electrode are carried out, respectively, in the disk discharge grinding process. In addition, with design of experiments on PCD machining, different Disk EDM parameters are obtained to evaluate the influence of dominant factors on machining speed and surface quality. Optimal gap reference voltage, wheel rotational speed and pulse width are extracted, respectively, under the conditions of two electrode materials. Results show that pulse width plays the most important role in machining, and copper electrode can effectively produce smoother surface than graphite when used as electrode in Disk EDM. Moreover, edge fabrication of spiral miller (φ125 mm) is precisely realized with circular run-out errors less than 0.050 mm.

show abstract

Section: Introductionmentioning

confidence: 99%

Edge fabrication and process optimization of precision woodworking PCD millers with disk electrical discharge machining

Zhang

et al. 2015

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Literature review shows that many researchers have studied glass machining process which involves single-point diamond turning tool [3,4], conventional grinding wheel [5][6][7][8][9][10][11][12], and milling cutter [13][14][15]. However, the hardness and brittleness of glass makes these mechanically micro-machining processes problematic due to damage resulting to brittle fracture, cutting forceinduced tool deflection or breakage, and tool wear [16]. On the other hand, micro-tools made of polycrystalline diamond (PCD) meet up this challenge for micro-machining of hard and brittle materials.…”

Section: Introductionmentioning

confidence: 99%

“…In addition, Morgan et al [16,25] has fabricated the PCD and tungsten carbide tool combining the process of the wire EDG and micro-EDM. The study involved only the preliminary test of micro-grinding of soda lime and ultralow expansion glass and micro-drilling of conductive material using fabricated tools.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass

Perveen

San

Rahman

2011

Int J Adv Manuf Technol

View full text Add to dashboard Cite

With the demand for microstructures of not only with diversified shape but also of reduced dimension on glass, fabrication of polycrystalline diamond (PCD) tool/ microelectrodes with different shape has become important. However, to date, fabrication of different shapes in single setup is not possible and also needs special indexing attachment. To solve this problem, in this study, a specially designed block containing three v-slots of 60°, 90°, and 120°has been designed and fabricated using wire cut. Thereafter with the help of block electro-discharge machining method and using this specially designed block, different shapes of microelectrodes with symmetrical and non-symmetrical section has been fabricated. This study also investigates the feasibility of using these different geometry PCD tool for micro-grinding of BK7 glass. In this context, a relative study on the micro-grinding performance of four different geometry tools (circular, D-shaped, triangular, and square) has been carried out. It has been observed that among the different shaped tools, D-shaped tool experienced lowest cutting force along x-and y-axes where as triangular tool faced lowest force along z-axis, and highest cutting forces were found to be experienced by square tool. Average and maximum roughness of machined surface was found to be improved from circular to others tool except triangular one. But, it was also observed that side surface started to deteriorate from circular to other tool due to edge wear. In case of tool wear, square and triangular tool experienced more wear than circular and D-shaped tool due to their frequent edge blunting or rounding effect. Finally, among four different geometry tools, D-shaped tool was considered to provide better performance in terms of the achieved surface finish, tool wear, and cutting force analysis.

show abstract

“…-Brittle materials are difficult to mechanically micromachine by cutting processes like milling due to damage resulting from material removal by brittle fracture which leads to rough surfaces requiring subsequent polishing steps. Material removal by ductile regime instead of brittle fractures is made possible by using polycrystalline diamond tools (Morgan et al 2004). Mechanical sawing, though limited to simple straight patterns has also proved successful (Plaza et al 2003).…”

Section: Introductionmentioning

confidence: 99%

Deep microstructuring in glass for microfluidic applications

et al. 2006

View full text Add to dashboard Cite

Glass is widely used as a structural and functional material in micro-total-analysis-systems. Two low-cost techniques have been used to produce deep and vertical microstructures into glass. A commercially available photosensitive glass (Foturanä) is patterned by photolithography and etched in an HF solution for the construction of a microfluidic component. Channels and reservoirs were bonded to a poly(dimethylsiloxane) cover. A two-level structure with various depths (reservoirs and channels) was also made by a double exposure through two different masks. The other technique uses micro-ultra-sonic machining to form channels by erosion into borosilicate glass (Pyrex 7740). The two structuring techniques are compared with respect to surface profiles and surface states.

show abstract

Micro machining glass with polycrystalline diamond tools shaped by micro electro discharge machining

Cited by 116 publications

References 11 publications

Edge fabrication and process optimization of precision woodworking PCD millers with disk electrical discharge machining

Edge fabrication and process optimization of precision woodworking PCD millers with disk electrical discharge machining

Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass

Deep microstructuring in glass for microfluidic applications

Contact Info

Product

Resources

About