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Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass

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Abstract

With the demand for microstructures of not only with diversified shape but also of reduced dimension on glass, fabrication of polycrystalline diamond (PCD) tool/microelectrodes with different shape has become important. However, to date, fabrication of different shapes in single setup is not possible and also needs special indexing attachment. To solve this problem, in this study, a specially designed block containing three v-slots of 60°, 90°, and 120° has been designed and fabricated using wire cut. Thereafter with the help of block electro-discharge machining method and using this specially designed block, different shapes of microelectrodes with symmetrical and non-symmetrical section has been fabricated. This study also investigates the feasibility of using these different geometry PCD tool for micro-grinding of BK7 glass. In this context, a relative study on the micro-grinding performance of four different geometry tools (circular, D-shaped, triangular, and square) has been carried out. It has been observed that among the different shaped tools, D-shaped tool experienced lowest cutting force along x- and y-axes where as triangular tool faced lowest force along z-axis, and highest cutting forces were found to be experienced by square tool. Average and maximum roughness of machined surface was found to be improved from circular to others tool except triangular one. But, it was also observed that side surface started to deteriorate from circular to other tool due to edge wear. In case of tool wear, square and triangular tool experienced more wear than circular and D-shaped tool due to their frequent edge blunting or rounding effect. Finally, among four different geometry tools, D-shaped tool was considered to provide better performance in terms of the achieved surface finish, tool wear, and cutting force analysis.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National University of Singapore, 10 Kent Ridge Crescents, Singapore, 119260, Singapore

    Asma Perveen, Wong Yoke San & Mustafizur Rahman

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  1. Asma Perveen
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  2. Wong Yoke San
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  3. Mustafizur Rahman
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Correspondence to Asma Perveen.

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Perveen, A., San, W.Y. & Rahman, M. Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass. Int J Adv Manuf Technol 61, 101–115 (2012). https://doi.org/10.1007/s00170-011-3688-5

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  • DOI: https://doi.org/10.1007/s00170-011-3688-5

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