Skip to main content
SpringerLink
Log in

Edge breakage mechanism of optical glass surface in ultrasonic vibration-assisted milling

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Optical glass is an isotropic amorphous solid material; due to its excellent performance, it has been widely used in various fields. However, during the milling process, the optical glass will have defects such as edge break damage and cracks on the surface, import and export, and side edges; these defects seriously affect the application of optical glass. In order to study the formation mechanism of defects such as edge break damage and cracks during optical glass processing and experimental and theoretical study of optical glass milling using ultrasonic vibration-assisted milling (UVAM), the edge break damage depth model of the export edge collapse was established. The results show that the main reason for the edge break damage is that the optical glass will crack on the subsurface during processing; the propagation of these cracks causes the amorphous material to tear and crumble. By comparing and analyzing the results of ultrasonic vibration milling and ordinary milling, ultrasonic vibration can significantly reduce this phenomenon, and it is found that the cutting depth and feed per tooth have a great influence on the export edge break damage value, and the influence of spindle speed is less. In addition, when the amplitude of the ultrasonic wave is applied, not only the import and export edge break damage phenomenon can be significantly improved, but also the surface quality can be significantly improved. Therefore, the application of ultrasonic vibration-assisted milling to the processing of optical glass can improve the surface and edge quality, which is help improve the application range of optical glass.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Data availability

Not applicable.

Code availability

Not applicable.

References

  1. O’Toole L, Kang C, Fang F (2019) Advances in rotary ultrasonic-assisted machining. Nanomanufacturing Metrol. https://doi.org/10.1007/s41871-019-00053-3

    Article  Google Scholar 

  2. Kim T, Kwon K-K, Chu CN, Song KY (2020) Experimental investigation on CO2 laser-assisted micro-slot milling characteristics of borosilicate glass. Precis Eng 63:137–147. https://doi.org/10.1016/j.precisioneng.2020.02

    Article  Google Scholar 

  3. Zhao PY, Zhou M, Liu XL, Jiang B (2020) Effect to the surface composition in ultrasonic vibration-assisted grinding of BK7 optical glass. Appl Sci 10(2):516. https://doi.org/10.3390/app10020516

    Article  Google Scholar 

  4. Liu J, Chen G, Ren C, Qin X, Zou Y, Ge J (2020) Effects of axial and longitudinal-torsional vibration on fiber removal in ultrasonic vibration helical milling of CFRP composites. J Manuf Process 58:868–883. https://doi.org/10.1016/j.jmapro.2020.08.071

    Article  Google Scholar 

  5. Verma GC, Pandey PM (2018) Machining forces in ultrasonic-vibration assisted end milling. Ultrasonics. https://doi.org/10.1016/j.ultras.2018.07.004

    Article  PubMed  Google Scholar 

  6. Sui H, Zhang X, Zhang D, Jiang X, Wu R (2017) Feasibility study of high-speed ultrasonic vibration cutting titanium alloy. J Mater Process Technol 247:111–120. https://doi.org/10.1016/j.jmatprotec.2017.03.017

    Article  Google Scholar 

  7. Baraheni M, Amini S (2019) Predicting subsurface damage in silicon nitride ceramics subjected to rotary ultrasonic assisted face grinding. Ceram Int 45(8):10086–10096. https://doi.org/10.1016/j.ceramint.2019.02.055

    Article  CAS  Google Scholar 

  8. Chen Y, Su H, Qian N, He J, Gu J, Xu J, Ding K (2021) Ultrasonic vibration-assisted grinding of silicon carbide ceramics based on actual amplitude measurement: grinding force and surface quality. Ceram Int 47(11):15433–15441. https://doi.org/10.1016/j.ceramint.2021.02.109

    Article  CAS  Google Scholar 

  9. Jia D, Li C, Zhang Y, Yang M, Zhang X, Li R, Ji H (2019) Experimental evaluation of surface topographies of NMQL grinding ZrO2 ceramics combining multiangle ultrasonic vibration. Int J Adv Manuf Technol 100(1):457–473. https://doi.org/10.1007/s00170-018-2718-y

    Article  Google Scholar 

  10. Fang B, Yuan Z, Li D, Gao L (2021) Effect of ultrasonic vibration on finished quality in ultrasonic vibration assisted micromilling of Inconel718. Chin J Aeronaut 34(6):209–219. https://doi.org/10.1016/j.cja.2020.09.021

    Article  Google Scholar 

  11. Yang Y, Yang M, Li C, Li R, Said Z, Ali HM, Sharma S (2022) Machinability of ultrasonic vibration assisted micro-grinding in biological bone using nanolubricant. Front Mech Eng 12:1–8. https://doi.org/10.1007/s11465-022-0717-z

    Article  Google Scholar 

  12. Yan Y, Zhang Y, Zhao B, Liu J (2021) Surface formation and damage mechanisms of nano-ZrO2 ceramics under axial ultrasonic-assisted grinding. J Mech Sci Technol 35(3):1187–1197. https://doi.org/10.1007/s12206-021-0232-x

    Article  Google Scholar 

  13. Esmaeilzare A, Rahimi A, Rezaei SM (2014) Investigation of subsurface damages and surface roughness in grinding process of Zerodur® glass–ceramic. Appl Surf Sci 313:67–75. https://doi.org/10.1016/j.apsusc.2014.05.137

    Article  CAS  Google Scholar 

  14. Li HN, Yu TB, Zhu LD, Wang WS (2016) Evaluation of grinding-induced subsurface damage in optical glass BK7. J Mater Process Technol 229:785–794. https://doi.org/10.1016/j.jmatprotec.2015.11.003

    Article  CAS  Google Scholar 

  15. Yao Z, Gu W, Li K (2012) Relationship between surface roughness and subsurface crack depth during grinding of optical glass BK7. J Mater Process Technol 212(4):969–976. https://doi.org/10.1016/j.jmatprotec.2011.12.007

    Article  CAS  Google Scholar 

  16. Niu J, Zhao, & Gao. (2019) Investigation of cutting force in longitudinal-torsional ultrasonic-assisted milling of Ti-6Al-4V. Materials 12(12):1955. https://doi.org/10.3390/ma12121955

    Article  ADS  CAS  PubMed  PubMed Central  Google Scholar 

  17. Huang C, Zhou M, Zhang H (2021) A cutting force prediction model in axial ultrasonic vibration end grinding for BK7 optical glass considering protrusion height of abrasive grits. Measurement 180:109512. https://doi.org/10.1016/j.measurement.2021.109512

    Article  Google Scholar 

  18. Zhang C, Liang Y, Zhang T, Chen X, Zhao J, Yu T (2021) Study on machining BK7 optical glass by ultrasonic vibration-assisted polishing considering the micro-contact state of the abrasive particles with the workpiece. J Manuf Process 72:469–482. https://doi.org/10.1016/j.jmapro.2021.10.033

    Article  Google Scholar 

  19. Ma YJ, Nie WZ, Lu JM, Chen H (2020) Study on surface quality of BK7 optical glass by longitudinal torsional composite ultrasonic vibration milling. Mater Sci Forum 984:51–57. https://doi.org/10.4028/www.scientific.net/msf.984.51

    Article  Google Scholar 

  20. Jin X, Xie B (2015) Experimental study on surface generation in vibration-assisted micro-milling of glass. Int J Adv Manuf Technol 81(1–4):507–512. https://doi.org/10.1007/s00170-015-7211-2

    Article  Google Scholar 

  21. Amin M, Yuan S, Israr A, Zhen L, Qi W (2017) Development of cutting force prediction model for vibration-assisted slot milling of carbon fiber reinforced polymers. Int J Adv Manuf Technol 94(9–12):3863–3874. https://doi.org/10.1007/s00170-017-1087-2

    Article  Google Scholar 

  22. Gong H, Fang FZ, Zhang XF, Du J, Hu XT (2013) Study on the reduction strategy of machining-induced edge chipping based on finite element analysis of in-process workpiece structure. J Manuf Sci Eng 135(1):011017. https://doi.org/10.1115/1.4023458

    Article  Google Scholar 

  23. BrianLawn (2010) Fracture Mechanics of Brittle Solids:2 Edition [M]. Higher Education Press

  24. Lambropoulos JC, Jacobs SD, Ruckman J (1999) Material removal mechanisms from grinding to polishing. Ceram Trans 102:113–128

    Google Scholar 

  25. Li ZC, Jiao Y, Deines TW, Pei ZJ, Treadwell C (2005) Rotary ultrasonic machining of ceramic matrix composites: feasibility study and designed experiments. Int J Mach Tools Manuf 45(12–13):1402–1411. https://doi.org/10.1016/j.ijmachtools.2005.01.034

    Article  Google Scholar 

Download references

Funding

This research is supported by the Doctoral Foundation of Henan Polytechnic University (Grant No. B2017-31) and the National Natural Science Foundation of China project “Research on subsurface damage mechanism of ceramic matrix composites machined by high speed multi-dimensional ultrasonic” (Grant No. 52005164).

Author information

Authors and Affiliations

  1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, Henan, China

    Jinglin Tong, Shuaikun Yang, Yanqiu Ye, Zhipeng Zhang, Chaosheng Song & Xiaobo Wang

Authors
  1. Jinglin Tong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shuaikun Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yanqiu Ye
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zhipeng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Chaosheng Song
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Xiaobo Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Jinglin Tong: Initial draft, funding acquisition.

Shuaikun Yang: Theoretical analysis, methodology.

Yanqiu Ye: Writing editing, paper format arrangement.

Zhipeng Zhang: Picture arrangement.

Chaosheng Song: Paper format arrangement.

Xiaobo Wang: Writing—review and editing.

Corresponding author

Correspondence to Jinglin Tong.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Tong, J., Yang, S., Ye, Y. et al. Edge breakage mechanism of optical glass surface in ultrasonic vibration-assisted milling. Int J Adv Manuf Technol 131, 2265–2278 (2024). https://doi.org/10.1007/s00170-023-11093-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11093-x

Keywords

Search

Navigation