Abstract:
The most common variety of glass is soda-lime glass, also known as soda-lime-silica
glass, which is the material that we've selected as our workpiece material, and the cutting
tool is Multilayer – PVD TiN-coated tungsten carbide. Because of the brittle nature of
soda-lime glass, its machining is challenging. Soda-lime glass is a material that is
affected by strain rate and temperature. As a result, high-speed machining (HSM) may be
advantageous in obtaining a ductile surface with minimal roughness for which, the right
combinations of cutting parameters must be identified. The Response Surface
Methodology (RSM) is used in this study for optimization. Surface roughness depends on
cutting speed, feed per tooth, and coating type. For the best outcomes, RSM would find
the ideal combination of all three criteria. The design of the experiment is a critical
component of our project since it determines the parameters under which we will execute
our experiment. We used the Design Expert software to plan our experiment. Factorial
designs, randomized designs, and response surface analysis are all possible with this
software. The Design Expert generated parameters will be used to guide the trial runs.
The outcomes of the trials will be used to do an RSM analysis and create empirical
models for forecasting tool wear and surface roughness. Our goal will be to achieve a
minimum no of damaged flutes and surface roughness. We shall utilize the RSM's
Desirability Function to optimize the cutting conditions. Coated carbide tools are
recommended for machining glass due to the coating reducing chipping and cracking of
the glass, leading to improved surface finish and reduced tool wear. Our study on ductile
mode end milling of soda-lime glass found that coated carbide tools resulted in
significantly lower surface roughness values and better tool performance compared to
uncoated tools, indicating that coated carbide tools are more effective in glass machining
than uncoated tools.
