Experimental investigation and multi-objective optimization of Nd:YAG laser micro-channeling process of zirconia dental ceramic

Abdo, Basem M. A.; El-Tamimi, Abdulaziz M.; Anwar, Saqib; Umer, Usama; Al‐Ahmari, Abdulrahman; Ghaleb, Mageed

doi:10.1007/s00170-018-2374-2

Cited by 47 publications

(17 citation statements)

References 41 publications

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“…However, the mechanical properties of the injection molds fabricated by Al-filled epoxy resins are inferior to metallic molds. Thus, some reinforcing fillers such as wollastonite, molybdenum disulfide [ 52 ], glass sphere, zirconia [ 53 , 54 , 55 ], silica sand, glass fibers , or silicon nitride [ 56 , 57 , 58 ] were recommended to add in the matrix materials. Additionally, metal AM technologies such as DB [ 59 ], SLS [ 60 , 61 ], SLM [ 62 ], electron beam melting, or direct metal laser sintering were recommended for manufacturing injection molds with optimum CCCs for mass production of wax patterns.…”

Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.

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Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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“…Excessive edge chipping, high tool wear, and high cutting forces result in high processing costs of machining Al 2 O 3 by traditional processes such as diamond grinding [ 5 ]. Even non-conventional processes (for example, the laser ablation process) produce thermal damage, and poor surface roughness and accuracy [ 6 , 7 ]. Low material removal rate and poor dimensional accuracy have been the main drawbacks reported while machining alumina bioceramic using ultrasonic machining (USM) and abrasive machining [ 8 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Analysis on the Influence and Optimization of μ-RUM Parameters in Machining Alumina Bioceramic

et al. 2019

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Fabrication of precise micro-features in bioceramic materials is still a challenging task. This is because of the inherent properties of bioceramics, such as low fracture toughness, high hardness, and brittleness. This paper places an emphasis on investigating the multi-objective optimization of fabrication of microchannels in alumina (Al2O3) bioceramics by using rotary ultrasonic machining (RUM). The influence of five major input parameters, namely vibration frequency, vibration amplitude, spindle speed, depth of cut, and feed rate on the surface quality, edge chipping, and dimensional accuracy of the milled microchannels was analyzed. Surface morphology and microstructure of the machined microchannels were also evaluated and analyzed. Unlike in previous studies, the effect of vibration frequency on the surface morphology and roughness is discussed in detail. A set of designed experiments based on central composite design (CCD) method was carried out. Main effect plots and surface plots were analyzed to detect the significance of RUM input parameters on the outputs. Later, a multi-objective genetic algorithm (MOGA) was employed to determine the optimal parametric conditions for minimizing the surface roughness, edge chipping, and dimensional errors of the machined microchannels. The optimized values of the surface roughness (Ra and Rt), side edge chipping (SEC), bed edge chipping (BEC), depth error (DE), and width error (WE) achieved through the multi-objective optimization were 0.27 μm, 2.7 μm, 8.7 μm, 8 μm, 5%, and 5.2%, respectively.

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“…Before the final experiments were implemented, the selection of the laser and RUM key input parameters was essential. In this analysis, the process parameter ranges were specified based on previous studies of laser machining [45,47,[54][55][56][57] and RUM [58][59][60][61][62]. The preliminary experiments were also conducted to establish the exact levels of the process parameters which were later used for the final experiments.…”

Section: Machining Conditionsmentioning

confidence: 99%

Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes

et al. 2020

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Micromachining has gained considerable interest across a wide range of applications. It ensures the production of microfeatures such as microchannels, micropockets, etc. Typically, the manufacturing of microchannels in bioceramics is a demanding task. The ubiquitous technologies, laser beam machining (LBM) and rotary ultrasonic machining (RUM), have tremendous potential. However, again, these machining methods do have inherent problems. LBM has issues concerning thermal damage, high surface roughness, and vulnerable dimensional accuracy. Likewise, RUM is associated with high machining costs and low material-removal rates. To overcome their limits, a synthesis of LBM and RUM processes known as laser rotary ultrasonic machining (LRUM) has been conceived. The bioceramic known as biolox forte was utilized in this investigation. The approach encompasses the exploratory study of the effects of fundamental input process parameters of LBM and RUM on the surface quality, machining time, and dimensional accuracy of the manufactured microchannels. The performance of LRUM was analyzed and the mechanism of LRUM tool wear was also investigated. The results revealed that the surface roughness, depth error, and width error is decreased by 88%, 70%, and 80% respectively in the LRUM process. Moreover, the machining time of LRUM is reduced by 85%.

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Experimental investigation and multi-objective optimization of Nd:YAG laser micro-channeling process of zirconia dental ceramic

Cited by 47 publications

References 41 publications

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Experimental Analysis on the Influence and Optimization of μ-RUM Parameters in Machining Alumina Bioceramic

Micromachining of Biolox Forte Ceramic Utilizing Combined Laser/Ultrasonic Processes

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