Multi-response optimizations for high speed ductile mode machining of soda lime glass

Ductile regime end milling of soda lime glass needs consideration from commercial standpoints as well as in research and development. High speed machining is capable to obtain ductile mode at an increased material removal rate and at the same time tool wear rate can be optimized at higher value of cutting speed. This paper presents a simple and workable approach to process parameters optimization, to achieve ductile mode machining of soda lime glass applying high speed using the experiment design and parameter optimization capabilities of Response Surface Methodology (RSM). The particular ranges of cutting parameters were chosen based on initial tests conducted to ensure ductile mode machining during the experiments. The machining parameters such as cutting speed, depth of cut, and feed rate were varied from 30000 to 50000 rpm, 20 to 50 μm and from 45 to 75 mm/min (0.45 to 1.25 μm per tooth) respectively. Based on the experimental results empirical mathematical models relating the machining parameters to response parameters, namely, surface roughness, tool wear and tool life, were first developed. Multi-criteria optimization was conducted applying the desirability function of RSM based on the developed models, with the aim of determining the combination of machining parameters that would lead to optimal settings of responses. The quality criteria considered to establish optimal parameters were the minimization of surface roughness (Ra), tool wear (Tw) and maximization of tool life (Tl). Obtained results demonstrated that optimal combination of the response parameters, 0.78 μm Ra, 107 μm (Tw) and 0.56 min (Tl) were achieved with maximum desirability 77%, at the lowest depth of cut 20 μm at spindle speed of approximately 40000 rpm with feed rate of 69 mm/min

Achievement of ductile regime machining in high speed end milling of soda lime glass by using tungsten carbide tool insert

Soda lime glass is widely used in optics, chemical apparatus, camera lens, micro gas turbines, light bulbs etc. on account of its high hardness, corrosion resistance, and excellent optical properties. These require high dimensional accuracy and flawless surface finish. However, soda lime glass is inherently brittle leading to subsurface crack propagation and fracture which compromise its functionality. To avoid these defects, the machining needs to be performed under ductile mode conditions. Therefore, this research investigates the viability and requisite conditions for achieving ductile regime machining(DRM) in high speed micro-end milling of soda lime glass. Machining was performed at high cutting speeds (30,000 to 50,000 rpm), feed rate (5 to 15 mm/min), and depth of cut (3 to 7 μm). A surface profilometer was then used to measure the surface roughness and a scanning electron microscope (SEM) used to scrutinize the resultant machined surfaces. The results demonstrate that ductile streaks and rounded gummy chips (without sharp or jagged edges) are produced in all runs. In addition, there are no subsurface cracks and the minimum surface roughness attained is 0.08μm. These indicate that DRM of soda lime glass is obtainable using high-speed micro end milling in a conventional end mill with tungsten carbide inserts

Proceedings of International Technical Postgraduate Conference 2022

This conference proceedings contains articles on the various research ideas of the academic & research communities presented at the International Technical Postgraduate Conference 2022 (TECH POST 2022) that was held at Universiti Malaya, Kuala Lumpur, Malaysia on 24-25 September 2022. TECH POST 2022 was organized by the Faculty of Engineering, Universiti Malaya. The theme of the conference is “Embracing Innovative Engineering Technologies Towards a Sustainable Future”.  TECH POST 2022 conference is intended to foster the dissemination of state-of-the-art research from five main disciplines of Engineering: Electrical Engineering, Biomedical Engineering, Civil Engineering, Mechanical Engineering, and Chemical Engineering. The objectives of TECH POST 2022 are to bring together innovative researchers from all engineering disciplines to a common forum, promote R&D activities in Engineering, and promote the dissemination of scientific knowledge and research know-how between researchers, engineers, and students. Conference Title: International Technical Postgraduate Conference 2022Conference Acronym: TECH POST 2022Conference Date: 24-25 September 2022Conference Location: Faculty of Engineering, Universiti Malaya, Kuala Lumpur Malaysia (Hybrid Mode)Conference Organizers: Faculty of Engineering, Universiti Malaya, Kuala Lumpur, Malaysia