A review on the rotary ultrasonic machining of advanced ceramics

Advanced ceramics are likely candidates for many industrial applications due to their superior properties. However, their high machining costs lead to limited applications. Rotary ultrasonic machining (RUM) is one of the cost-effective machining processes available for drilling holes in advanced ceramics. This paper reports on investigations in the last few years on RUM process of advanced ceramics. Emphasis is given on the effect of RUM process parameters (such as applied static load, rotational speed, ultrasonic power and vibration amplitude, abrasive grit size and coolant) on machinability parameters (such as material removal rate, tool wear and surface roughness). Results on tool wear and edge chipping are also reported

Surface microstructural changes of spark plasma sintered zirconia after grinding and annealing

Spark plasma sintered zirconia (3Y-TZP) specimens have been produced of 140 nm 372 nm and 753 nm grain sizes by sintering at 1250 °C, 1450 °C and 1600 °C, respectively. The sintered zirconia specimens were grinded using a diamond grinding disc with an average diamond particle size of about 60 µm, under a pressure of 0.9 MPa. The influence of grinding and annealing on the grain size has been analysed. It was shown that thermal etching after a ruff grinding of specimens at 1100 °C for one hour induced an irregular surface layer of about a few hundred nanometres in thickness of recrystallized nano-grains, independently of the initial grain size. However, if the ground specimens were exposed to higher temperature, e.g. annealing at 1575 °C for one hour, the nano-grain layer was not observed. The resulted grain size was similar to that achieved by the same heat treatments on carefully polished specimens. Therefore, by appropriate grinding and thermal etching treatments, nanograined surface layer can be obtained which increases the resistance to low temperature degradation.Peer ReviewedPostprint (author's final draft

Design of ultraprecision machine tools with application to manufacturing of miniature and micro components

Currently the underlying necessities for predictability, producibility and productivity remain big issues in ultraprecision machining of miniature/microproducts. The demand on rapid and economic fabrication of miniature/microproducts with complex shapes has also made new challenges for ultraprecision machine tool design. In this paper the design for an ultraprecision machine tool is introduced by describing its key machine elements and machine tool design procedures. The focus is on the review and assessment of the state-of-the-art ultraprecision machining tools. It also illustrates the application promise of miniature/microproducts. The trends on machine tool development, tooling, workpiece material and machining processes are pointed out

Brittleness index of machinable dental materials and its relation to the marginal chipping factor

OBJECTIVES: The machinability of a material can be measured with the calculation of its brittleness index (BI). It is possible that different materials with different BI could produce restorations with varied marginal integrity. The degree of marginal chipping of a milled restoration can be estimated by the calculation of the marginal chipping factor (CF). The aim of this study is to investigate any possible correlation between the BI of machinable dental materials and the CF of the final restorations. METHODS: The CERECTM system was used to mill a wide range of materials used with that system; namely the Paradigm MZ100TM (3M/ESPE), Vita Mark II (VITA), ProCAD (Ivoclar-Vivadent) and IPS e.max CAD (Ivoclar-Vivadent). A Vickers hardness Tester was used for the calculation of BI, while for the calculation of CF the percentage of marginal chipping of crowns prepared with bevelled marginal angulations was estimated. RESULTS: The results of this study showed that Paradigm MZ100 had the lowest BI and CF, while IPS e.max CAD demonstrated the highest BI and CF. Vita Mark II and ProCAD had similar BI and CF and were lying between the above materials. Statistical analysis of the results showed that there is a perfect positive correlation between BI and CF for all the materials. CONCLUSIONS: The BI and CF could be both regarded as indicators of a material’s machinability. Within the limitations of this study it was shown that as the BI increases so does the potential for marginal chipping, indicating that the BI of a material can be used as a predictor of the CF

The effects of lapping load in finishing advanced ceramic balls on a novel eccentric lapping machine

HIPed (Hot Isostatically Pressed) silicon nitride ball blanks were lapped from diameter 13.255 mm to diameter 12.7 mm by a novel eccentric lapping machine. A maximum material removal rate of 68 μm/hour has been achieved under a nominal lapping load of 43 N/ball. It was found that the material removal rate was increasing almost linearly with the lapping load within this load range. When the lapping load was higher than 43 N/ball, the material removal rate started to drop and the lapped ball roundness error started to increase. At the highest nominal lapping load of 107 N/ball, surface and subsurface damages were found on the lapped balls. Because of eccentric loading effect, the actual load on individual ball could be 25~28% higher than the nominal lapping load. The surface residual stresses of lapped balls under different lapping loads were measured, and it was found that the lapping load had less effect than previous HIP process. Rolling contact fatigue tests were conducted on balls lapped at nominal loads of 43N/ball and 107 N/ball. No failure occurred on the ball lapped at 43 N/ball after 138 million stress cycles. Ball lapped at 107 N/ball was failed after 13.3 million stress cycles with a shallow spall with flat bottom inside. This research suggests that the lapping load for advanced ceramic balls in conventional concentric lapping could be doubled from 20N/ball to 40 N/ball without degrading the surface quality of lapped balls

Examination of the material removal mechanisms during the lapping process of advanced ceramic rolling elements

Two types of HIPed Si3N4 bearing ball blanks with different surface hardness and fracture toughness were lapped under various loads, speeds, and lubricants using a novel eccentric lapping machine. The lapped surfaces were examined by optical microscope and SEM. The experimental results show that the material removal rate for type I ball blanks were 3-4-fold of type 2 in most cases. Different lapping fluids affected the material removal rate at lower lapping loads, but they had much less influence on the material removal rate at higher lapping loads. The SEM micrographs reveal that the grain pullout prevailed on the lapped surface of type I ball blanks, and the surface of type 2 featured bulk material removal by microcracking. Under extreme high lapping load, surface cracks and damages were found, and SEM with EDX disclosed steel from the lapping plate had transferred to the ceramic ball surface. The preliminary conclusion is that the material removal mechanism during the lapping process of silicon nitride balls using this eccentric lapping machine is mainly mechanical abrasive wear. Lawn and Wilshaw's indentation model on brittle materials is used to explain the difference in material removal rate for the two types of ball blanks

Sub-surface damage issues for effective fabrication of large optics

A new ultra precision large optics grinding machine, BoX®has been developed at Cranfield University. BoX®islocated at the UK's Ultra Precision Surfaces laboratory at the OpTIC Technium. This machine offers a rapidand economic solution for grinding large off-axis aspherical and free-form optical components.This paper presents an analysis of subsurface damage assessments of optical ground materials produced usingdiamond resin bonded grinding wheels. The specific materials used, Zerodur®and ULE®are currently understudy for making extremely large telescope (ELT) segmented mirrors such as in the E-ELT project.The grinding experiments have been conducted on the BoX®grinding machine using wheels with grits sizes of76 μm, 46 μm and 25 μm. Grinding process data was collected using a Kistler dynamometer platform. Thehighest material removal rate (187.5 mm3/s) used ensures that a 1 metre diameter optic can be ground in lessthan 10 hours. The surface roughness and surface profile were measured using a Form Talysurf. The subsurfacedamage was revealed using a sub aperture polishing process in combination with an etching technique.These results are compared with the targeted form accuracy of 1 μm p-v over a 1 metre part, surface roughnessof 50-150 nm RMS and subsurface damage in the range of 2-5 μm. This process stage was validated on a 400mm ULE®blank and a 1 metre hexagonal Z

Analysis of Flexural Strength and Contact Pressure After Simulated Chairside Adjustment of Pressed Lithium Disilicate Glass-Ceramic

Statement of problem Research evaluating load-to-failure of pressed lithium disilicate glass-ceramic (LDGC) with a clinically validated test after adjustment and repair procedures is scarce. Purpose The purpose of this in vitro study was to investigate the effect of the simulated chairside adjustment of the intaglio surface of monolithic pressed LDGC and procedures intended to repair damage. Material and methods A total of 423 IPS e.max Press (Ivoclar Vivadent AG) disks (15 mm diameter, 1 mm height) were used in the study. The material was tested by using an equibiaxial loading arrangement (n≥30/group) and a contact pressure test (n≥20/group). Specimens were assigned to 1 of 14 groups. One-half was assigned to the equibiaxial load test and the other half underwent contact pressure testing. Testing was performed in 2 parts, before glazing and after glazing. Before-glazing specimens were devested and entered in the test protocol, while after-glazing specimens were devested and glazed before entering the test protocol. Equibiaxial flexure test specimens were placed on a ring-on-ring apparatus and loaded until failure. Contact pressure specimens were cemented to epoxy resin blocks with a resin cement and loaded with a 50-mm diameter hemisphere until failure. Tests were performed on a universal testing machine with a crosshead speed of 0.5 mm/min. Weibull statistics and likelihood ratio contour plots determined intergroup differences (95% confidence bounds). Results Before glazing, the equibiaxial flexural strength test and the Weibull and likelihood ratio contour plots demonstrated a significantly higher failure strength for 1EC (188 MPa) than that of the damaged and/or repaired groups. Glazing following diamond-adjustment (1EGG) was the most beneficial post-damage procedure (176 MPa). Regarding the contact pressure test, the Weibull and likelihood ratio contour plots revealed no significant difference between the 1PC (98 MPa) and 1PGG (98 MPa) groups. Diamond-adjustment, without glazing (1EG and 1PG), resulted in the next-to-lowest equibiaxial flexure strength and the lowest contact pressure. After glazing, the strength of all the groups, when subjected to glazing following devesting, increased in comparison with corresponding groups in the before-glazing part of the study. Conclusions A glazing treatment improved the mechanical properties of diamond-adjusted IPS e.max Press disks when evaluated by equibiaxial flexure and contact pressure tests. Clinical Implications When adjustments are made on the intaglio surface of a pressed lithium disilicate glass-ceramic, a subsequent glazing treatment is recommended to improve strength