Surface and subsurface damage in Zerodur® glass ceramic during ultrasonic assisted grinding

Lakhdari, Fouad; Bouzid, D.; Belkhir, Nabil; Herold, Volker

doi:10.1007/s00170-016-9551-y

Cited by 31 publications

(13 citation statements)

References 22 publications

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“…Besides, because the prediction results mainly rely on surface roughness, subsurface cracks may propagate to a large depth beneath a relatively smooth surface [63]. Lakhdari et al [30] found that SSD depth induced in ultrasonically assisted grinding was 35% less than the conventional grinding, even the surface quality is worse.…”

Section: Predictive Methodsmentioning

confidence: 99%

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Methods for Detection of Subsurface Damage: A Review

Yin

Bai

2018

Chin. J. Mech. Eng.

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Subsurface damage is easily induced in machining of hard and brittle materials because of their particular mechanical and physical properties. It is detrimental to the strength, performance and lifetime of a machined part. To manufacture a high quality part, it is necessary to detect and remove the machining induced subsurface damage by the subsequent processes. However, subsurface damage is often covered with a smearing layer generated in a machining process, it is rather difficult to directly observe and detect by optical microscopy. An efficient detection of subsurface damage directly leads to quality improvement and time saving for machining of hard and brittle materials. This paper presents a review of the methods for detection of subsurface damage, both destructive and non-destructive. Although more reliable, destructive methods are typically time-consuming and confined to local damage information. Non-destructive methods usually suffer from uncertainty factors, but may provide global information on subsurface damage distribution. These methods are promising because they can provide a capacity of rapid scan and detection of subsurface damage in spatial distribution.

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Section: Predictive Methodsmentioning

confidence: 99%

“…The depth of SSD is calculated by measuring the characteristic dimensions of the dimple. There are also some other forms of dimpling [30]. The ball dimpling method is simple in operation and low in cost.…”

Section: Dimplingmentioning

confidence: 99%

Methods for Detection of Subsurface Damage: A Review

Yin

Bai

2018

Chin. J. Mech. Eng.

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“…Figure 2 c shows a sample of the actual machined pocket. The prior literature reporting the micro-machining of brittle materials using RUM [ 23 , 26 , 34 , 35 ] and the results of the preliminary experiments were utilized to choose the appropriate range of RUM parameters. The vibration frequency of the used RUM cutting tool was measured and found that the resonance ranges to be between 20 and 30 kHz.…”

Section: Methodsmentioning

confidence: 99%

“…The key benefit of RUM is its ability to manufacture high precision high surface quality of the components and tool life extension [ 19 , 20 ]. It can be considered for both brittle and difficult to process materials for micro/macro machining [ 21 , 22 , 23 ]. RUM has lately been used in Al 2 O 3 materials for milling micro-channels and drilling micro-holes.…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization of Processing Parameters for Micro-Pockets on Alumina Bioceramic Using Rotary Ultrasonic Machining

et al. 2020

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The machining of ceramic materials is challenging and often impossible to realize with conventional machining tools. In various manufacturing applications, rotary ultrasonic milling (RUM) shows strengths, in particular for the development of high-quality micro-features in ceramic materials. The main variables that influence the performance and price of the product are surface roughness, edge chipping (EC), and material removal rate (MRR) during the processing of ceramics. RUM has been considered in this research for the milling of micro-pockets in bioceramic alumina (Al2O3). Response surface methodology in the context of a central composite design (CCD) is being used to plan the experiments. The impacts of important RUM input parameters concerning cutting speed, feed rate, depth of cut, frequency, and amplitude have been explored on the surface roughness in terms of arithmetic mean value (Ra), the EC, and the MRR of the machined pockets. The main effect and the interaction effect of the implemented RUM parameters show that by providing a lower feed rate and cutting depth levels and elevated frequency and cutting speed, the Ra and the EC can be minimized. At greater levels of feed rate and cutting depth, higher MRR can be obtained. The influence of RUM input parameters on the surface morphology was also recorded and analyzed using scanning electron microscopic (SEM) images. The study of the energy dispersive spectroscopy (EDS) shows that there is no modification in the alumina bioceramic material. Additionally, a multi-response optimization method has been applied by employing a desirability approach with the core objectives of minimizing the EC and Ra and maximizing the MRR of the milled pockets. The obtained experimental values for Ra, EC, and MRR at an optimized parametric setting were 0.301 µm, 12.45 µm, and 0.873 mm3/min respectively with a combined desirability index value of 0.73.

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“…Moreover, RUM can be used to produce components with high surface quality and high dimensional accuracy without altering their physical properties [11][12][13]. It can be used for micro/macro machining both brittle materials such as glass and hard to machine materials [14][15][16]. For example, Jain and Pandey [14] applied RUM for drilling micro-holes (300 µm dia.)…”

Section: Introductionmentioning

confidence: 99%

Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

2020

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Pocket milling has been regarded as one of the most widely used operations in machining. The surface quality of the machined pockets is an essential aspect of any engineering and medical applications. In the current study, rotary ultrasonic machining (RUM) was applied for milling micro-pockets on alumina (Al2O3) ceramic. The objective of this research was to analyze the effect of the tool overlapping parameters on the surface roughness, surface morphology and the profiles of the machined pockets. Subsequently, the effect of different tool path strategies was analyzed on the surface quality and the material removal rate (MRR) of the machined pockets. A scanning electron microscope is used for analyzing the tool wear mechanisms. The experimental results provide evidence that the surface roughness, surface morphology and the MRR have been significantly affected by the considered tool overlapping and the tool path strategies. Furthermore, among the selected tool overlapping parameters (5–25%) and the tool path strategies, the best surface roughness (Ra = 0.155 μm and Rt = 1.432 µm) of the machined pockets can be found at 20% of the tool overlapping with a mix of uni-directional and zigzag tool path strategy.

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Surface and subsurface damage in Zerodur® glass ceramic during ultrasonic assisted grinding

Cited by 31 publications

References 22 publications

Methods for Detection of Subsurface Damage: A Review

Methods for Detection of Subsurface Damage: A Review

Multi-Response Optimization of Processing Parameters for Micro-Pockets on Alumina Bioceramic Using Rotary Ultrasonic Machining

Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

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