Skip to main content
SpringerLink
Log in

Surface quality study of longitudinal torsional ultrasonic micro-milling of borosilicate glass based on morphological modeling

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

Abstract

Borosilicate glass has good light transmittance and stable chemical property, which is an ideal material for microfluidic chip matrix, However, brittle fracture is easy to occur during processing, which is a typical material difficult to process. This limits the surface accuracy. In recent years, longitudinal torsional ultrasonic vibration–assisted milling (LTUVAM) has been proposed as an effective way to machine hard and brittle materials. To elucidate the mechanism of material removal methods and elaborate the material removal mechanism during longitudinal torsional ultrasonic vibration–assisted milling process, this paper established a 3D morphology prediction model to investigate the material removal method. Firstly, the three-dimensional surface morphology model was created by describing the intricate tool path and the workpiece surface morphology reconstruction process under ultrasonic conditions while also considering the tool run-out effect. The model exhibited a certain degree of scalability, enabling the acquisition of various process morphology prediction models by altering the tool coordinates via matrix manipulation. Secondly, the accuracy of the model was verified by longitudinal torsional ultrasonic processing experiments. Thirdly, longitudinal torsional ultrasonic vibration–assisted milling experiments and longitudinal ultrasonic vibration–assisted milling experiments were conducted, and the surface roughness of the machined workpieces was measured. The experimental results show that LTUVAM further reduces the roughness compared with LUVAM, indicating that the reduction ratio reaches a maximum value of 61.06% at the spindle speed of 16,000 RPM, and then, the reduction ratio decreases to 42.88% with the increase of spindle speed. Combining modeling and experimental results, we concluded that LTUVAM was more advantageous in achieving plastic material removal and enhancing the surface quality of the machined surface compared to LUVAM. And under the same process conditions, as the spindle speed increases, the surface roughness of the workpiece increases first and then decreases.

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
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

References

  1. El-Taybany Y, Hossam M, El-Hofy H (2017) Experimental investigation of ultrasonic-assisted milling of soda glass using factorial design of experiments. Procedia CIRP 58:381–386. https://doi.org/10.1016/j.procir.2017.03.238

    Article  Google Scholar 

  2. Antwi EK, Liu K, Wang H (2018) A review on ductile mode cutting of brittle materials. Front Mech Eng 13:251–263. https://doi.org/10.1007/s11465-018-0504-z

    Article  Google Scholar 

  3. Chen F, Mei GJ, Zhao B, Bie WB, Li GX (2020) Study on the characteristics of zirconia ceramic in three-dimensional ultrasonic vibration-assisted ELID internal grinding. J Mech Sci Technol 34:333–344. https://doi.org/10.1007/s12206-019-1233-x

    Article  Google Scholar 

  4. Gu G, Wu S, Wang D, Zhou S, Zhu LD (2023) An QL, Guo H. A review of the research on the variation of tool’s motion trajectory and its influence on the formation mechanism of surface quality in ultrasonic vibration machining. J Manuf Process 107:294–319. https://doi.org/10.1016/j.jmapro.2023.10.025

    Article  Google Scholar 

  5. Chen J, An QL, Ming WW, Chen M (2020) Investigation on machined surface quality in ultrasonic-assisted grinding of C f/SiC composites based on fracture mechanism of carbon fibers. Int J Adv Manuf Technol 109:1583–1599. https://doi.org/10.1007/s00170-020-05739-3

    Article  Google Scholar 

  6. Zhang JG, Zhang JJ, Cui T, Hao ZW, Zahrani AA (2017) Sculpturing of single crystal silicon microstructures by elliptical vibration cutting. J Manuf Process 29:389–398. https://doi.org/10.1016/j.jmapro.2017.09.003

    Article  Google Scholar 

  7. 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 

  8. Layegh KSE, Lazoglu I (2017) 3D surface topography analysis in 5-axis ball-end milling. CIRP Ann 66(1):133–136. https://doi.org/10.1016/j.cirp.2017.04.021

    Article  Google Scholar 

  9. Buj-Corral I, Vivancos-Calvet J (2011) González-Rojas H (2011) Influence of feed, eccentricity and helix angle on topography obtained in side milling processes. Int J Mach Tools Manuf 51(12):889–897. https://doi.org/10.1016/j.ijmachtools.2011.08.001

    Article  Google Scholar 

  10. Song W, Liu Z, Yao G, Khan AM, Cai Y (2022) Effect of workpiece work hardening on machined surface topography generated in two-step milling process. J Manuf Process 77:348–360. https://doi.org/10.1016/j.jmapro.2022.03.039

    Article  Google Scholar 

  11. Lu XH, Hu XC, Jia ZY, Liu MY, Gao S, Qu CL, Liang SY (2018) Model for the prediction of 3D surface topography and surface roughness in micro-milling Inconel 718. Int J Adv Manuf Tech 94:2043–2056. https://doi.org/10.1007/s00170-017-1001-y

    Article  Google Scholar 

  12. Yang D, Liu ZQ (2015) Surface plastic deformation and surface topography prediction in peripheral milling with variable pitch end mill. Int J Mach Tool Manu 91:43–53. https://doi.org/10.1016/j.ijmachtools.2014.11.009

    Article  Google Scholar 

  13. Cai CY, An QL, Chen M, Ming W (2023) Modelling of end-milled floor surface topography considering system vibration and tool deflection. J Mater Process Tech 312:117864. https://doi.org/10.1016/j.jmatprotec.2023.117864

    Article  Google Scholar 

  14. Arizmendi M, Jiménez A (2019) Modelling and analysis of surface topography generated in face milling operations. Int J Mech Sci 163:105061. https://doi.org/10.1016/j.ijmecsci.2019.105061

    Article  Google Scholar 

  15. Wang LP, Ge SY, Si H, Guan LW, Duan FY, Liu YZ (2020) Elliptical model for surface topography prediction in five-axis flank milling. Chinese J Aeronaut 33(4):1361–1374. https://doi.org/10.1016/j.cja.2019.06.007

    Article  Google Scholar 

  16. Wang LP, Ge SY, Si H, Yuan X, Duan FY (2020) Roughness control method for five-axis flank milling based on the analysis of surface topography. Int J Mech Sci 169:105337. https://doi.org/10.1016/j.ijmecsci.2019.105337

    Article  Google Scholar 

  17. Wang T, Wu XY, Zhang GQ, Xu B, Chen YH, Ruan SC (2021) Theoretical study on frequency spectrum characteristics of surface profiles generated in micro-end-milling process. Int J Adv Manuf Tech 113(3–4):893–906. https://doi.org/10.1007/s00170-021-06686-3

    Article  Google Scholar 

  18. Juri AZ, Belli R, Lohbauer U, Ebendorff-Heidepriem H, Yin L (2023) Edge chipping damage in lithium silicate glass-ceramics induced by conventional and ultrasonic vibration-assisted diamond machining. Dent Mater 39(6):557–567. https://doi.org/10.1016/j.dental.2023.04.001

    Article  Google Scholar 

  19. Zhang CL, Feng PF, Zhang JF (2013) Ultrasonic vibration-assisted scratch-induced characteristics of C-plane sapphire with a spherical indenter. Int J Mach Tool Manu 64:38–48. https://doi.org/10.1016/j.ijmachtools.2012.07.009

    Article  Google Scholar 

  20. Huang WH, Yu DP, Zhang XQ, Zhang M, Chen DS (2018) Ductile-regime machining model for ultrasonic elliptical vibration cutting of brittle materials. J Manuf Process 36:68–76. https://doi.org/10.1016/j.jmapro.2018.09.029

    Article  Google Scholar 

  21. Zhang JG, Zhang JJ, Cui T, Al HZW, Zahrani A (2017) Sculpturing of single crystal silicon microstructures by elliptical vibration cutting. J Manuf Process 29:389–398. https://doi.org/10.1016/j.jmapro.2017.09.003

    Article  Google Scholar 

  22. Juri AZ, Song XF, Nakanishi Y, Dudley J, Jamieson L, Yin L (2023) Surface fractures in pre-crystallized and crystallized zirconia-containing lithium silicate glass-ceramics generated in ultrasonic vibration-assisted machining. J Mech Behav Biomed 147:106132. https://doi.org/10.1016/j.jmbbm.2023.106132

    Article  Google Scholar 

  23. Qin SQ, Zhu LD, Wiercigroch M, Ren TY, Hao YP, Ning JS, Zhao JZ (2022) Material removal and surface generation in longitudinal-torsional ultrasonic assisted milling. Int J Mech Sci 227:107375. https://doi.org/10.1016/j.ijmecsci.2022.107375

    Article  Google Scholar 

Download references

Funding

The authors wish to acknowledge the financial support for this research from the Post-doctoral Later-stage Foundation Project of Shenzhen Polytechnic University (Project No. 6021271001 K), the Natural Science Foundation of Shandong Province (Grant No. ZR2020QE180), the Key Research and Development Plan of Shandong Province (No. 2023CXPT014 and 2021JMRH0301), the Visiting Study and Training of Teachers from Provincial General Undergraduate Universities in Shandong Province, and the Domestic Visiting Scholar of Shandong Jianzhu University.

Author information

Authors and Affiliations

  1. School of Mechanical and Electrical Engineering, Shandong Jianzhu University, Jinan, 250101, China

    Jie Yi & Xiaojie Liu

  2. Institute of Ultrasonic Technology, Institute of Intelligent Manufacturing Technology, Shenzhen Polytechnic University, Shenzhen, 518055, China

    Xiaojie Liu, Tao Wang, Wei Chen, Tao Gong & Yizhi Shao

  3. School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Jie Yi & Qinghua Song

Authors
  1. Jie Yi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xiaojie Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tao Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Qinghua Song
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Wei Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Tao Gong
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Yizhi Shao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors participated in the work of the paper. J.Y.: conceptualization, methodology, writing—review and editing, funding acquisition. X.L.: supervision, writing—original draft, methodology. T.W.: supervision, methodology, writing—review and editing, funding acquisition. Q.S.: supervision, methodology. W.C.: methodology, funding acquisition. T.G.: supervision, analysis. Y.S.: analysis. All authors have read and agreed to the published version of the manuscript.

Corresponding author

Correspondence to Tao Wang.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

The authors declare that they participated in this research work.

Consent for publication

The authors declare that they agreed to publish the research results.

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

Yi, J., Liu, X., Wang, T. et al. Surface quality study of longitudinal torsional ultrasonic micro-milling of borosilicate glass based on morphological modeling. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13753-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s00170-024-13753-y

Keywords

Search

Navigation