Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass

Soda lime glass is used extensively in camera lens, micro gas turbines, light bulbs, tablewares, optics, and chemical apparatus owing to its high hardness, excellent optical properties, and good corrosion and chemical resistance. Such applications of soda lime glass demand high machining and finishi...

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Main Authors:	Amin, A. K. M. Nurul, Omar, A.A. Che, Kamal, M.A.Mohammed, Nassar, Mahmoud M.A., Zaib, N.F. Mohd, Arif, Muammer Din
Format:	Article
Language:	English English
Published:	Trans Tech Publications Ltd., Switzerland 2015
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/46257/ http://irep.iium.edu.my/46257/ http://irep.iium.edu.my/46257/ http://irep.iium.edu.my/46257/1/First_page_Effect_of_Cutter_Dia_on_Surf_Rough_in_Soda_Lime_HSM.gif http://irep.iium.edu.my/46257/5/AMR.1115.51_Effect_of_Cutter_Dia_on_Surf_Rough_in_HSM_of_Soda_Lime_Glass.pdf

id	iium-46257
recordtype	eprints
spelling	iium-462572015-12-29T03:34:42Z http://irep.iium.edu.my/46257/ Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass Amin, A. K. M. Nurul Omar, A.A. Che Kamal, M.A.Mohammed Nassar, Mahmoud M.A. Zaib, N.F. Mohd Arif, Muammer Din TJ Mechanical engineering and machinery Soda lime glass is used extensively in camera lens, micro gas turbines, light bulbs, tablewares, optics, and chemical apparatus owing to its high hardness, excellent optical properties, and good corrosion and chemical resistance. Such applications of soda lime glass demand high machining and finishing precision. On the other hand, machining of glass poses significant challenges due to its inherent brittleness. The process of removal of material from glass, if not done in ductile mode, can generate subsurface cracks and brittle fractures which have adverse effects on its functionality. This research investigates the high speed micro-end milling of soda lime glass in order to obtain ductile regime machining. It has been found by other researchers that ductile mode machining can avoid sub-surface cracks and brittle fractures. However, in ductile mode machining, the gummy chips settle permanently on the machined surface affecting adversely the surface finish. In order to avoid such chip settlement, compressed air was directed using a special air delivery nozzle to blow away the resultant gummy chips, thereby preventing them from settling on the machined surface. Response surface methodology (RSM) and a commercial NC end mill were used to design and perform the machining runs, respectively. Machining was done using: high spindle speeds from 30,000 to 50,000 rpm, feed rates from 5 to 15 mm/min, and depth of cuts from 3 to 7 μm. Three different diameter carbide tools were used: 0.5, 1, and 2 mm. A surface profilometer was used to analyze the surface roughness of the resultant machined surface. Subsequently, the data was used for finding the best combination of cutting parameters required to obtain the lowest surface roughness. The results demonstrate that high speed machining is a viable option for obtaining ductile regime machining and generating machined surfaces with very low surface roughness in the range of 0.08μm – 0.22 μm, using 0.5 mm carbide end mill cutter. Trans Tech Publications Ltd., Switzerland 2015-07 Article PeerReviewed application/pdf en http://irep.iium.edu.my/46257/1/First_page_Effect_of_Cutter_Dia_on_Surf_Rough_in_Soda_Lime_HSM.gif application/pdf en http://irep.iium.edu.my/46257/5/AMR.1115.51_Effect_of_Cutter_Dia_on_Surf_Rough_in_HSM_of_Soda_Lime_Glass.pdf Amin, A. K. M. Nurul and Omar, A.A. Che and Kamal, M.A.Mohammed and Nassar, Mahmoud M.A. and Zaib, N.F. Mohd and Arif, Muammer Din (2015) Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass. Advanced Materials Research, 1115. pp. 51-54. ISSN 1662-8985 http://www.scientific.net/AMR.1115.51 10.4028/www.scientific.net/AMR.1115.51
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Amin, A. K. M. Nurul Omar, A.A. Che Kamal, M.A.Mohammed Nassar, Mahmoud M.A. Zaib, N.F. Mohd Arif, Muammer Din Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass
description	Soda lime glass is used extensively in camera lens, micro gas turbines, light bulbs, tablewares, optics, and chemical apparatus owing to its high hardness, excellent optical properties, and good corrosion and chemical resistance. Such applications of soda lime glass demand high machining and finishing precision. On the other hand, machining of glass poses significant challenges due to its inherent brittleness. The process of removal of material from glass, if not done in ductile mode, can generate subsurface cracks and brittle fractures which have adverse effects on its functionality. This research investigates the high speed micro-end milling of soda lime glass in order to obtain ductile regime machining. It has been found by other researchers that ductile mode machining can avoid sub-surface cracks and brittle fractures. However, in ductile mode machining, the gummy chips settle permanently on the machined surface affecting adversely the surface finish. In order to avoid such chip settlement, compressed air was directed using a special air delivery nozzle to blow away the resultant gummy chips, thereby preventing them from settling on the machined surface. Response surface methodology (RSM) and a commercial NC end mill were used to design and perform the machining runs, respectively. Machining was done using: high spindle speeds from 30,000 to 50,000 rpm, feed rates from 5 to 15 mm/min, and depth of cuts from 3 to 7 μm. Three different diameter carbide tools were used: 0.5, 1, and 2 mm. A surface profilometer was used to analyze the surface roughness of the resultant machined surface. Subsequently, the data was used for finding the best combination of cutting parameters required to obtain the lowest surface roughness. The results demonstrate that high speed machining is a viable option for obtaining ductile regime machining and generating machined surfaces with very low surface roughness in the range of 0.08μm – 0.22 μm, using 0.5 mm carbide end mill cutter.
format	Article
author	Amin, A. K. M. Nurul Omar, A.A. Che Kamal, M.A.Mohammed Nassar, Mahmoud M.A. Zaib, N.F. Mohd Arif, Muammer Din
author_facet	Amin, A. K. M. Nurul Omar, A.A. Che Kamal, M.A.Mohammed Nassar, Mahmoud M.A. Zaib, N.F. Mohd Arif, Muammer Din
author_sort	Amin, A. K. M. Nurul
title	Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass
title_short	Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass
title_full	Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass
title_fullStr	Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass
title_full_unstemmed	Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass
title_sort	effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass
publisher	Trans Tech Publications Ltd., Switzerland
publishDate	2015
url	http://irep.iium.edu.my/46257/ http://irep.iium.edu.my/46257/ http://irep.iium.edu.my/46257/ http://irep.iium.edu.my/46257/1/First_page_Effect_of_Cutter_Dia_on_Surf_Rough_in_Soda_Lime_HSM.gif http://irep.iium.edu.my/46257/5/AMR.1115.51_Effect_of_Cutter_Dia_on_Surf_Rough_in_HSM_of_Soda_Lime_Glass.pdf
first_indexed	2018-09-07T06:41:04Z
last_indexed	2018-09-07T06:41:04Z
_version_	1610929892726145024

Effect of cutter diameters on surface roughness attained in high speed end milling of soda lime glass

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