Enhancement and verification of a machined surface quality for glass milling operation using CBN grinding tool—Taguchi approach

  • M. Sayuti
  • Ahmed A. D. Sarhan
  • M. Fadzil
  • M. Hamdi


Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters set-up, making the machining process on the glass excellent in manufacturing complicated special products compared with other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. Taguchi optimization method was used to estimate optimum machining parameters with standard orthogonal array L16 (44) to replace the conventional trial and error method as it is time-consuming. Moreover, analyses on surface roughness and cutting force are applied which are partial determinant of the quality of surface and cutting process. These analyses are conducted using signal to noise (S/N) response analysis and the analysis of variance (Pareto ANOVA) to determine which process parameters are statistically significant. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness and cutting forces. These parameters include the lubrication pressure, spindle speed, feed rate, and depth of cut as control factors. While, the lubrication direction is considered as a noise factor in the experiments. Finally, verification tests are carried out to investigate the improvement of the optimization. The results showed an improvement of 49.02% and 26.28% in the surface roughness and cutting force performance, respectively.


CNC machine Glass milling Grinding Taguchi Optimization Surface roughness Cutting force 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.



The authors are grateful to the University of Malaya, Malaysia for the financial support (UMRG-RG094/10AET). The authors are also thankful to the Center of Advanced Manufacturing and Material Processing, Department of Design and Manufacture, Faculty of Engineering, University of Malaya for providing excellent laboratories facilities to conduct this research.


  1. 1.
    Bourhis EL (2007) Glass: mechanics and technology. Wiley-VCH, WeinheimGoogle Scholar
  2. 2.
    Doering R, Nishi Y (2007) Handbook of semiconductor manufacturing technology. CRC, Boca RatonCrossRefGoogle Scholar
  3. 3.
    Yin L, Huang H (2008) Brittle materials in nano-abrasive fabrication of optical mirror-surface. Precis Eng 32:336–341MathSciNetCrossRefGoogle Scholar
  4. 4.
    Zhong ZW, Lee WY (2001) Grinding of silicone and glass using a new dressing device and an improved lubrication system. J Mater Manuf Process 16(4):471–482CrossRefGoogle Scholar
  5. 5.
    Zhang B (1999) Helical scan grinding of brittle and ductile materials. J Mater Process Technol 91:196–205CrossRefGoogle Scholar
  6. 6.
    Tsai YH, Chen JC, Lou SJ (1999) In-process surface recognition system based on neural networks in end milling cutting operations. Int J Mach Tool Manuf 39(4):583–605CrossRefGoogle Scholar
  7. 7.
    Grujicic M, Pandurangan B, Coutris N, Cheeseman BA, Fountzoulas C, Patel P, Templeton DW, Bishnoi KD (2009) A simple ballistic material model for soda-lime glass. Int J Impact Eng 36:386–401CrossRefGoogle Scholar
  8. 8.
    Zhong ZW (2002) Surface finish of precision machined advanced materials. J Mater Process Technol 122:173–178CrossRefGoogle Scholar
  9. 9.
    Zhang JZ, Chen JC, Kirby ED (2007) Surface roughness optimization in an end-milling operation using the Taguchi design method. J Mater Process Technol 184:233–239CrossRefGoogle Scholar
  10. 10.
    Ghani JA, Choudhury IA, Hassan HH (2004) Application of Taguchi method in the optimization of end milling. J Mater Process Technol 145(1):84–92CrossRefGoogle Scholar
  11. 11.
    Sayuti M, Sarhan AAD, Hamdi M (2011) Optimizing the machining parameters in glass grinding operation on the CNC milling machine for best surface roughness. Adv Mater Res 154–155:721–726Google Scholar
  12. 12.
    Huang H (2003) Machining characteristics and surface integrity of yytria stabilized tetragonal zirconia in high deep grinding. Mater Sci Eng 345:155–163CrossRefGoogle Scholar
  13. 13.
    Xie GZ, Huang H (2008) An experimental investigation of temperature in high speed deep grinding of partially stabilized zirconia. Int J Mach Tools Manuf New Delhi 48:1562–1568CrossRefGoogle Scholar
  14. 14.
    Yang B, Shen X, Lei S (2009) Mechanisms of edge chipping in laser-assisted milling of silicon nitride ceramics. Int J Mach Tools Manuf 49:344–350CrossRefGoogle Scholar
  15. 15.
    Shirakashi T, Obikawa T (2003) Feasibility of gentle mode machining of brittle materials and its condition. J Mater Process Technol 138:522–526CrossRefGoogle Scholar
  16. 16.
    Li HZ, Li XP (2002) Milling force prediction using a dynamic shear length model. Int J Mach Tool Manuf 42:277–286CrossRefGoogle Scholar
  17. 17.
    Huang H, Liu YC (2003) Experimental investigations of machining characteristics and removal mechanisms of advanced ceramics in high speed deep grinding. Int J Mach Tools Manuf 43:811–823CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Limited 2011

Authors and Affiliations

  • M. Sayuti
    • 1
  • Ahmed A. D. Sarhan
    • 1
    • 2
  • M. Fadzil
    • 1
  • M. Hamdi
    • 1
  1. 1.Centre of Advanced Manufacturing and Material Processing, Department of Engineering Design and ManufactureUniversity of MalayaKuala LumpurMalaysia
  2. 2.Department of Mechanical Engineering, Faculty of EngineeringAssiut UniversityAssiutEgypt

Personalised recommendations