The electrostatic charges encountered by a cutting tool when turning advanced contact lenses are important as they reflect the quality and condition of the tool, machine, fixture, and sometimes even the surface finished which is responsible for tool wear and poor surface quality. This study investigates the influence of cutting parameters namely cutting speed, feed rate and depth of cut on electrostatic charge (ESC) which play the leading role in determining the machine economics and quality of machining contact lens polymers. An electrostatic charge model based on response surface statistical method is developed for reliably predicting the values of static charging based on its relationship to cutting parameters in ultra-high precision diamond turning of contact lenses. It is clearly seen that all the model terms are significant with cutting speed having the highest degree of significance followed by feed rate and the interaction of speed and feed. However, depth of cut has the lowest degree of significance on the electrostatics charge.
This study present measurements of electrostatic charge that were performed in order to obtain the factors that influence the charging behaviour in the diamond turning process of advanced contact lens polymers. This can be used to decrease tool wear provided that tribo-electric tool wear is dominant in cutting contact lens polymers. The effective medical application of contact lenses is heavily dependent on their form accuracy and surface integrity. Tribo-electric charge which occurs when cutting polymeric contact lenses play a key role, having direct influence on the targeted form accuracy and surface quality of contact lenses. The research goal is to find out what parameter determine the amount of tribo-electric tool wear. The analysis of variance (ANOVA) was used to establish the statistical significance of the cutting parameters on Tribo-electric charge. The results revealed that depth of cut of cut strongly affects the Tribo-electric charge followed by cutting speed, feed rate and interaction between depth and speed.
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