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Technical Briefs

Rotary Ultrasonic Machining of Alumina Dental Ceramics: A Preliminary Experimental Study on Surface and Subsurface Damages

[+] Author and Article Information
Yasser Ahmed, Matthew R. Stanco

Department of Industrial and Systems Engineering,
North Carolina Agricultural & Technical State University,
Greensboro, NC 27411

W. L. Cong

Department of Industrial and Manufacturing Systems
Engineering,
Kansas State University,
Manhattan, KS 66506

Z. G. Xu

Department of Mechanical Engineering,
North Carolina Agricultural & Technical State University,
Greensboro, NC 27411

Z. J. Pei

Department of Industrial and Manufacturing
Systems Engineering,
Kansas State University,
Manhattan, KS 66506

C. Treadwell

Sonic-Mill,
7500 Bluewater Road N.W.,
Albuquerque, NM 87121

Y. L. Zhu

New Breed Inc.,
4043 Piedmont Parkway,
High Point, NC 27265

Z. C. Li

Department of Industrial and Systems Engineering,
North Carolina Agricultural & Technical State University,
Greensboro, NC 27411
e-mail: zli@ncat.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received January 25, 2011; final manuscript received August 30, 2012; published online November 1, 2012. Assoc. Editor: Allen Y. Yi.

J. Manuf. Sci. Eng 134(6), 064501 (Nov 01, 2012) (5 pages) doi:10.1115/1.4007711 History: Received January 25, 2011; Revised August 30, 2012

This paper presents a preliminary study about effects of ultrasonic vibration on machined surface and subsurface damages in rotary ultrasonic machining (RUM). The surface and subsurface damages are compared for machining of dental ceramics (Al2O3) with and without ultrasonic vibration. The surface chippings are evaluated and the subsurface cracks are observed under scanning electron microscope (SEM).

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References

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Li, Z. C., Cai, L.-W., Pei, Z. J., and Treadwell, C., 2006, “Edge-Chipping Reduction in Rotary Ultrasonic Machining of Ceramics: Finite Element Analysis and Experimental Verification,” Int. J. Mach. Tools Manuf., 46(12–13), pp. 1469–1477. [CrossRef]
Churi, N. J., Pei, Z. J., Treadwell, C., and Shorter, D., 2009, “Rotary Ultrasonic Machining of Dental Ceramics,” Int. J. Mach. Mach. Mater., 6(3–4), pp. 270–284. [CrossRef]

Figures

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Fig. 4

SEM micrographs of surface quality and edge chipping resulted from diamond grinding and RUM

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Fig. 3

Illustration of workpiece preparation for SEM observation

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Fig. 2

Illustration of RUM process

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Fig. 1

Classic failure modes of dental ceramics (after Refs. [1] and [4])

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Fig. 5

The deepest subsurface crack resulted from diamond grinding (1500×)

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Fig. 6

A shallow subsurface crack resulted from diamond grinding (3500×)

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Fig. 7

Intergranular fracture and transgranular fracture observed for diamond grinding (5000×)

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Fig. 8

A subsurface crack resulted from RUM (5000×)

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Fig. 9

Illustration of RUM kinematics

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