Milling of Micro Grooves on Glass Cylinder Surfaces

Takashi Matsumura; Yoshihito Ueki

doi:10.20965/ijat.2011.p0011

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IJAT Vol.5 No.1 pp. 11-20

doi: 10.20965/ijat.2011.p0011

(2011)

Paper:

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Milling of Micro Grooves on Glass Cylinder Surfaces

Takashi Matsumura and Yoshihito Ueki

Tokyo Denki University, 2-2 Kanda Nishiki-cho, Chiyoda-ku, Tokyo 101-8457, Japan

Received:

August 2, 2010

Accepted:

October 14, 2010

Published:

January 5, 2011

Keywords:

end mill, glass, micro cutting, tool inclination, machining accuracy

Abstract

Micro milling is presented to machine micro grooves on a glass cylinder surface in a depth of cut of more than 10 µm. The milling tool is inclined in the cutter feed direction to finish fine surfaces in the operation. The effect of tool inclination on the cutting process during a rotation of the cutter is discussed in an analytical model. A 4-axis machine tool is developed to machine the micro grooves using the rotational and the linear motions. The cutting position on the cylinder surface is controlled to incline the milling tool in the cutting direction. Machining processes with a linear control in the longitudinal direction, with a rotational control of the workpiece, and with a simultaneous control of those motions are verified on the machine developed. Adjustment of workpiece alignment and pre-finishing are required for a high machining accuracy in the cutting operation. A feed rate of less than 0.24 mm/min is required to finish crack-free surfaces in cutting of fused silica.

Cite this article as:

T. Matsumura and Y. Ueki, “Milling of Micro Grooves on Glass Cylinder Surfaces,” Int. J. Automation Technol., Vol.5 No.1, pp. 11-20, 2011.

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References

[1] K. E. Puttick, M. R. Rudma, K. J. Smith, and A. K. Lindsey, “Single-Point Diamond Machining of Glasses,” Proc. R. Soc. London, Ser.A., Vol.426, pp. 19-30, 1989.
[2] T. G. Bifano, T. A. Dow, and R. O. Scattergood, “Ductile-Regime Grinding: A New Technology for Machining Brittle Materials,” Trans. of ASME, J. of Engineering for Industry, Vol.113, pp. 184-189, 1991.
[3] T. Nakatsuji, S. Kodera, S. Hara, H. Matsunaga, N. Ikawa, and S. Shimada, “Diamond Turning of Brittle Materials for Optical Components,” Annals of CIRP, Vol.39/1, pp. 89-92, 1990.
[4] I. Ogura and Y. Okazaki, “Ductile-Regime Machining of Optical Glasses by Means of Single Point Diamond Turning,” J. of the Japan Society for Precision Engineering, Vol.66, pp. 1431-1435, 2000.
[5] M. Yoshino, T. Aoki, and T. Shirakashi, “Scratching Test of Hardbrittle Materials under Hydrostatics Pressure,” Trans. of ASME, J. of Manufacturing Science and Engineering, Vol.123, pp. 231-239, 2001.
[6] M. V, Swain, “Microfracture scratch in brittle solids,” Proc. of Royal Society of London, Ser.A, pp. 575-579, 1979.
[7] R. Komanduri, D. A. Lucca, and Y. Tani, “Technological Advance in Fine Abrasive Processes,” Annals of CIRP, Vol.46/2, pp. 545-596, 1997.
[8] B. K. A. Ngoi and P. S. Sreejith, “Ductile Regime Finish Machining – A Review,” The Int. J. of Advanced Manufacturing Technology, Vol.16, pp. 547-550, 2000.
[9] T. Matsumura and T. Ono, “Cutting process of glass with inclined ball end mills,” J. of Material Processing Technology, Vol.200, pp. 356-363, 2008.
[10] T. Ono and T. Matsumura, “Influence of tool inclination on brittle fracture in glass cutting with ball end mills,” J. of Material Processing Technology, Vol.202, pp. 61-69, 2008.
[11] Y. Takeuchi, K. Sawada, and T. Sata, “Ultraprecision 3D Micromachining of Glass,” Annals of CIRP, Vol.45/1, pp. 401-404, 1996.
[12] T. Matsumura, Y. Miyahara, and T. Ono, “Dynamic Characteristics in The Cutting Operations with Small Diameter End Mills,” J. of Advanced Mechanical Design, Systems, and Manufacturing, Vol.2, No.4, pp. 609-618, 2008.
[13] K. Foy, Z. Wei, T. Matsumura, and Y. Huang, “Effect of tilt angle on cutting regime transition in glass micromilling,” Int. J. of Machine Tools & Manufacture, Vol.49, pp. 315-324, 2009.
[14] T. Matsumura and T. Ono, “Glass Machining with Ball End Mill,” Trans. of the North American Manufacturing Research Institution of SME, Vol.33, pp. 319-326, 2005.

This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

[1] [1] K. E. Puttick, M. R. Rudma, K. J. Smith, and A. K. Lindsey, “Single-Point Diamond Machining of Glasses,” Proc. R. Soc. London, Ser.A., Vol.426, pp. 19-30, 1989.

[2] [2] T. G. Bifano, T. A. Dow, and R. O. Scattergood, “Ductile-Regime Grinding: A New Technology for Machining Brittle Materials,” Trans. of ASME, J. of Engineering for Industry, Vol.113, pp. 184-189, 1991.

[3] [3] T. Nakatsuji, S. Kodera, S. Hara, H. Matsunaga, N. Ikawa, and S. Shimada, “Diamond Turning of Brittle Materials for Optical Components,” Annals of CIRP, Vol.39/1, pp. 89-92, 1990.

[4] [4] I. Ogura and Y. Okazaki, “Ductile-Regime Machining of Optical Glasses by Means of Single Point Diamond Turning,” J. of the Japan Society for Precision Engineering, Vol.66, pp. 1431-1435, 2000.

[5] [5] M. Yoshino, T. Aoki, and T. Shirakashi, “Scratching Test of Hardbrittle Materials under Hydrostatics Pressure,” Trans. of ASME, J. of Manufacturing Science and Engineering, Vol.123, pp. 231-239, 2001.

[6] [6] M. V, Swain, “Microfracture scratch in brittle solids,” Proc. of Royal Society of London, Ser.A, pp. 575-579, 1979.

[7] [7] R. Komanduri, D. A. Lucca, and Y. Tani, “Technological Advance in Fine Abrasive Processes,” Annals of CIRP, Vol.46/2, pp. 545-596, 1997.

[8] [8] B. K. A. Ngoi and P. S. Sreejith, “Ductile Regime Finish Machining – A Review,” The Int. J. of Advanced Manufacturing Technology, Vol.16, pp. 547-550, 2000.

[9] [9] T. Matsumura and T. Ono, “Cutting process of glass with inclined ball end mills,” J. of Material Processing Technology, Vol.200, pp. 356-363, 2008.

[10] [10] T. Ono and T. Matsumura, “Influence of tool inclination on brittle fracture in glass cutting with ball end mills,” J. of Material Processing Technology, Vol.202, pp. 61-69, 2008.

[11] [11] Y. Takeuchi, K. Sawada, and T. Sata, “Ultraprecision 3D Micromachining of Glass,” Annals of CIRP, Vol.45/1, pp. 401-404, 1996.

[12] [12] T. Matsumura, Y. Miyahara, and T. Ono, “Dynamic Characteristics in The Cutting Operations with Small Diameter End Mills,” J. of Advanced Mechanical Design, Systems, and Manufacturing, Vol.2, No.4, pp. 609-618, 2008.

[13] [13] K. Foy, Z. Wei, T. Matsumura, and Y. Huang, “Effect of tilt angle on cutting regime transition in glass micromilling,” Int. J. of Machine Tools & Manufacture, Vol.49, pp. 315-324, 2009.

[14] [14] T. Matsumura and T. Ono, “Glass Machining with Ball End Mill,” Trans. of the North American Manufacturing Research Institution of SME, Vol.33, pp. 319-326, 2005.