Micro machining glass with poly crystalline diamond tools shaped by micro electro discharge machining

Chris J. Morgan, R. Ryan Vallance, Eric Russell Marsh

    Research output: Contribution to journalArticle

    81 Citations (Scopus)

    Abstract

    Brittle materials are difficult to mechanically micro machine due to damage resulting from material removal by brittle fracture, cutting force-induced tool deflection or breakage and tool wear. This paper demonstrates the feasibility of micro machining glass materials with polycrystalline diamond (PCD) micro tools that are prepared in a variety of shapes using non-contact micro electro discharge machining. The PCD tools contain randomly distributed sharp protrusions of diamond with dimensions around l μm that serve as cutting edges for micro machining grooves in soda-lime glass and pockets in ultra-low expansion glass. Results indicate that smooth surfaces are obtained with process conditions allowing material removal by ductile regime cutting instead of brittle fractures, and the PCD tools show very little wear. With further improvements in material removal rate, micro machining with PCD tools is a promising approach for producing micro molds and micro fluidic devices in glass materials.

    Original languageEnglish (US)
    Pages (from-to)1687-1692
    Number of pages6
    JournalJournal of Micromechanics and Microengineering
    Volume14
    Issue number12
    DOIs
    StatePublished - Dec 1 2004

    Fingerprint

    Diamond
    Electric discharge machining
    machining
    Diamonds
    Machining
    diamonds
    Crystalline materials
    Glass
    glass
    Brittle fracture
    Wear of materials
    Fluidic devices
    Molds
    brittle materials
    Brittleness
    microfluidic devices
    Lime
    calcium oxides
    grooves
    deflection

    All Science Journal Classification (ASJC) codes

    • Electronic, Optical and Magnetic Materials
    • Mechanics of Materials
    • Mechanical Engineering
    • Electrical and Electronic Engineering

    Cite this

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    abstract = "Brittle materials are difficult to mechanically micro machine due to damage resulting from material removal by brittle fracture, cutting force-induced tool deflection or breakage and tool wear. This paper demonstrates the feasibility of micro machining glass materials with polycrystalline diamond (PCD) micro tools that are prepared in a variety of shapes using non-contact micro electro discharge machining. The PCD tools contain randomly distributed sharp protrusions of diamond with dimensions around l μm that serve as cutting edges for micro machining grooves in soda-lime glass and pockets in ultra-low expansion glass. Results indicate that smooth surfaces are obtained with process conditions allowing material removal by ductile regime cutting instead of brittle fractures, and the PCD tools show very little wear. With further improvements in material removal rate, micro machining with PCD tools is a promising approach for producing micro molds and micro fluidic devices in glass materials.",
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    Micro machining glass with poly crystalline diamond tools shaped by micro electro discharge machining. / Morgan, Chris J.; Vallance, R. Ryan; Marsh, Eric Russell.

    In: Journal of Micromechanics and Microengineering, Vol. 14, No. 12, 01.12.2004, p. 1687-1692.

    Research output: Contribution to journalArticle

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