Demands for producing high quality glass components have been increasing due to their superior mechanical and optical properties. However, due to their high hardness and brittleness, they present great challenges to researchers when developing new machining processes. In this work, the discrete element method (DEM) is used to simulate orthogonal machining of synthetic soda-lime glass workpieces that are created using a bonded particle model and installed with four different types of seed cracks. The effects of these seed cracks on machining performance are studied and predicted through the DEM simulation. It is found that cutting force, random cracks, and surface roughness are reduced by up to 90%, 74%, and 47%, respectively, for the workpieces with seed cracks compared to the regular ones. The results show that high performance machining through DEM simulation can be achieved with optimal seed cracks.
Materials such as glass and silicon dioxide have seen increased applications due to their advantageous properties including high strength and corrosion resistance. However, machining these materials are challenging due to their hard and brittle nature. Even though techniques such as abrasive jet machining have improved machining quality, they typically suffer from low productivity and poor surface integrity with subsurface cracks. This study focuses primarily on attaining high quality machined surface free from sub-surface cracks on BK7 samples by inducing microcracks on to the material. The hypothesis is that microcracks induced by femtosecond laser would synergistically assist the material removal process by weakening the material layer to be removed. As the first phase of research, the cracks are initiated starting from the material surface. Results show that machining laser-treated samples leads to on average 75% force reduction in comparison with machining untreated samples. Laser treated machined samples are produced without subsurface damages, and reduced tool wear is also noted.
Transparent, brittle materials, like glass, are used in various applications due to their advantages of mechanical and optical properties. However, their hard and brittle nature causes significant challenges to researchers when they design and test a new machining process. In order to optimize this time-consuming process, discrete element method (DEM) is applied to simulate the cutting process of soda-lime glass in this study. The first step is to create a synthetic material that behaves like soda-lime glass. Then, the macroproperties are calibrated by adjusting the microparameters of the DEM model to match the mechanical properties of the real soda-lime glass. Finally, orthogonal machining simulations are conducted and model validation are conducted by comparing the predicted cutting forces with those from the orthogonal cutting experiments.
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