Volume – 5 Special Issue – I February 2015 ISSN NO: 0976-2558

A REVIEW ON MACHINING PROCESS OF GLASS MATERIALS

Pravin Pawar Raj Ballav Amaresh Kumar

Ph.D Research Scholar,
Department of Manufacturing
Engineering, National Institute of
Technology, Jamshedpur,
Jharkhand 83101, India.
Email :pravin.1900@gmail.com
Associate Professor,
Department of Manufacturing
Engineering, National Institute of
Technology, Jamshedpur, Jharkhand
83101 India.
Email : rballav.prod@nitjsr.ac.in
Associate Professor,
Department of Manufacturing
Engineering, National Institute of
Technology, Jamshedpur, Jharkhand
83101 India.
Email : akumar.prod@nitjsr.ac.in

Abstract — This paper provides an intensive literature review to
enhance machining process on brittle materials glass taken into
consideration. The paper starts with the classification of current
& past manufacturing processes based on the processes being
used for machining of glass material. The major part of this
paper reviews existing machining processes used machined to
glass material reported over the past two decades, Finally this
paper attempts to identify output results with respective their
machining process.
I. INTRODUCTION
Glasses used as key structural material for optical, bio and
chemical devices due to their excellent & superior properties
such as high strength, hardness thermal resistance, corrosion
resistance, wear resistance, relatively light weight high
chemical and heat resistance, high electrical isolation, low
optical absorption, amorphous solid material, large optical
transmission range and biocompatibility
[6][9][12][34][38][35]. However, such materials are generally
difficult-to-machine due to the properties of extreme hardness,
brittleness[27][6][9][19].Glass also has the distinction of being
transparent and having low electrical as well as thermal
conductivity. It is increasingly being used in micro fabricated
devices like solid oxide fuel cells, pumps, optics, electronics
part, biomedical diagnostics, thermodynamics fluidics
reactors, micro-electromechanical systems(MEMS)[24][25]
[33][37][14][19]
II. CLASSIFICATION OF MACHINING PROCESS
A. Abrasive Water Jet Machining (AWJM)
The Authors investigated on machining of borosilicate
glass by AWJM. Depth of cut is measured with different
machine parameter of water pressure, abrasive flow rate,
traverse speed and standoff distance. Particle swarm
optimization is used to for optimization parameters [1].The
Surface roughness and kerf taper ratio aspect were studied of
machining of glass/epoxy composite laminate Material & also
produce a better quality of cuts for that Taguchi’s design tool
used for experiments and analysis of variance[2].The taper of
cut slot increases with increase in standoff distance. Garnet
abrasives produce a larger taper of cut followed by Al2O3 and
SiC. The taper of the cut also increases with increase in work
feed rate. The average width of cut produced by SiC is higher
in this case[15].Micro machining and fluid polishing of glass
using stagnation produced under the jet nozzle by using this
technique crack-free machining of micro grooves & polishing
of micro channels was done[21]
B. Micro Abrasive Air Jet Machining (MAJM)
Predictive mathematical models for the erosion rates in
micro-hole drilling and micro-channel cutting on glasses with
an abrasive air jet are developed. This model prediction
provides better experimental results[10] The Authors
conducted Machining of glass by abrasive jet machining while
the glass is cooled to a low temperature by using a liquid
Nitrogen. Due to this technique Material removal rate of glass
was increased [22].The experimented results shows that
micro-grooving on glass, Results obtaining that combination
of the fine-tuning of the masking process & MAJM. This is
applicable for micro-machining of semiconductors, electronic
devices & LCD[27].The author optimized machining
parameters such as Standoff distance, Pressures and different
Nozzle Diameters by using Taguchi Method & this method
compared to Analysis of Variance(ANOVA) The output
results found out MRR & KERF[30].In this paper discusses
abrasive-jet machining of glass by using silicon carbide or
aluminium oxide abrasives were mixed with air & directed at
high velocity onto the glass and because of that optimum
MRR was found to be 10mg/min[32] The Author has been
produced Analytical models for prediction of the shape,
sidewall slope, and depth of abrasive jet micro-machined
planar areas. In that developing two techniques (i) machining
micro-channels adjacent to the planned planar area, and (ii)
Target oscillation with an obliquely. This technique used for
machining of flat planar areas at a single elevation [11]
C. Abrasive Slurry Jet Micro Machining(ASJM)
The authors studied the effect of dilute polymer solutions on
the width, shape, and centreline roughness of micro-channels
machined using new developed abrasive slurry-jet micro-
machining (ASJM) apparatus. The results found out little

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Volume – 5 Special Issue – I
amount of polymer can affect decrease the width of machined
micro- channels[17] They found surface evolution model to
predict the profiles of micro-channel sand holes machined in
borosilicate glass for ASJM System. By using this model
accurately predicted the profiles of micro-channels with a
maximum error of 7% for aspect ratios (depth/ width) of up to
5[26]
D. Ultrasonic Machining (USM)
The author investigated surface formation mechanisms
involved in rotary ultrasonic machining (RUM) of a glass BK7
process. A novel theoretical model developed for RUM
process was connected by ultrasonic effects, such as the low
dynamic fracture toughness of the material, cyclical variation
in the effective work angle of the abrasive, and the larger
abrasive inertia force. It reduces cutting force of the diamond
tool without affecting surface quality of work-piece[8].The
researcher develops new method of micro ultrasonic
machining it achieves micro holes as small as 5μm in diameter
in quartz glass and silicon. The high tool wears problem
reduced by using a sintered diamond tool [9].The author
studied the influence of rotation of the work-piece in addition
to an ultrasonically oscillated tool was effective on MRR &
Surface Roughness, Also this technique is superior to
conventional ultrasonic machining [16]. In this aluminium
oxide or silicon carbide or boron carbide was mixed with
water and feds to a tool oscillating at frequencies between 15
& 20 kc/s and finding out material removal rate [32].The
author produced hybrid process of micro electrical-discharge
machining (MEDM) and micro ultrasonic vibration machining
(MUSM) is proposed for making precise micro-holes with
high aspect ratios in borosilicate glass type. In the roundness
investigations, the machining tool rotation speed had a close
relationship to the degree of micro-hole roundness. Using this
Micro-holes with a roundness value of about 2μm could be
obtained[33] The Authors Experimented results show that the
machining speed decreases with an increase in the static load
beyond a certain level also find out the debris accumulation
was proposed as the main reason leading to low machining
efficiency & particle size was the dominant element
influencing the surface [36] The authors demonstrate a process
in which USM added a low concentration hydrofluoric acid
solution with alumina slurry(CUSM). The output results
compare with conventional methods it shows that material
removal rate increase to 200% & also the surface roughness
was improved [6].
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February 2015 ISSN NO: 0976-2558
E. Electro Chemical Discharge Machining (ECDM)
The Author developed thermal model for the calculation of
material removal rate (MRR). The temperature distribution
within zone of influence of single spark is obtained by using
finite element method (FEM). The developed FEM based
thermal model was found to be in the similarity of accuracy
with the experimental results [3] In this author obtained micro-
structures less than 100μm in size, such as Ø60μm micro-
holes, a 10μm thin wall, and a 3D micro-structure were
fabricated in glass material by using micro ECDM process[5].
In this work experimented was done on electrochemical spark
abrasive drilling (ECSAD) process by using abrasive cutting
tools and find out output result such as material removal and
increased machined depth, Also abrasive cutting tool is
compared with conventional cutting tool [13]. The author
obtained in this research the high aspect ratio micro tools
fabricated in-house used in deep micro-hole drilling on glass
using low electrolyte concentration. An aspect ratio of 11 has
been achieved & surface features less than 100μm were
developed on glass for that purpose the tungsten carbide
micro-tool produced by using pulse electrochemical
micromachining (PECMM). The surface roughness was found
to be in the range of 250–350 nm. [14]. In this study, wire
electrochemical discharge machining (WECDM) was applied
to processing quartz glass with electrolyte supplied with
titrated flow. The investigated droplet titration approach to
machining of quartz glass required less cost and pollution free
[18]. In this researcher studied longitudinal oscillation applied
to the cathode electrode during the electrochemical discharge
micro drilling of glass and the effects of electrolyte flushing
alteration in both discharge and hydrodynamic regimes of the
process has been found out. In this experimentation
longitudinal waveform including square and sinusoidal were
applied to the tool. The experimented results show that
improvement in material removal rate (MRR) using square
waveform and a small amount of improvement in the
sinusoidal waveform. [28]
F. Laser Machining
This article examines ultrafast laser machining of tapered
micro channel trenches in both hard soda–lime and
borosilicate glasses. The author developed a model for channel
width and depth as a function of processing parameters and
threshold fluence calculated channel sizes from the model are
in good similar match’s experimental results [7]. The authors
got from this research a focused laser beam integrated with a
CAD-based scanning motion may be used effectively to
generate complex and highly precise micro features on glass
substrate [19] In this research short pulse solid-state lasers
with pulse duration in the nanosecond to femtosecond range
were used to process different types of glass materials. The
cause of the pulse duration and other process parameters on
the machined features was analyzed & their thermal effects
and nonlinear processes. Edge quality, circularity, aspect ratio,
formation of the redeposit material and machining rate were
investigated with about the process variables such as focusing
optics, laser power, wavelength and repetition rate[25].The
Volume – 5 Special Issue – I February 2015 ISSN NO: 0976-2558

400 W pulsed Nd–YAG laser used machined to a glass-matrix
composite optimising the laser pulse waveform parameters
with respect to both material removal rate/efficiency and
material damage [31].The researchers carried out methods,
including focused ion beam, Femto-second laser, KrF eximer
laser and dicing techniques, were used for preparing glassy
carbon micro-molds and results were in terms of the process
rate, quality of machined surface, quality of microstructures
on machined surface area and the shape of machined structure
[35] The author conducts machining of microgrooves on fused
silica substrates using a p-polarised femtosecond laser beam
was developed with groove profile and surface morphology.
Micro-channels with width and spacing of 20mm were
generated with no micro-cracks. The beam polarisation had
been affected machining results [38]
G. Acoustic Energy Micromachining(AE)
The author obtained AE energy in micro grinding is
sensitive to changes in the mechanism of material removal &
also material removal more AE energy in a plastic flow
dominated process than in a fracture-dominated process [4]
H. Nano Abrasion Machining (NAM)
The new method of Nano-abrasion machining is carried
out for optical finishing of brittle materials. The experiments
suggest that the material removal rate and surface roughness
are suitable for optical finishing. The flatness is improved
from 151 to 29 nm of optical glass of BK7 taking as a material
[12]
machining of Zerodur. In this chemical machining mechanism
for multi-phase multi-composite materials is identified. The
chemical property of the plasma jet is investigated via the
atom emission spectrum analysis method and the experimental
results of Zerodur material removal function and surface
roughness variation with different processing parameters are
investigated [34]
L. Micro Milling
In this paper find out ductile mode machining of glass by
micro milling process, Fracture-free slots have been cut in
soda-lime glass work-piece by micro-end milling.
Experimental results have investigated that fracture-free slots
can be machined in glass by micro milling process within
controlled set of cutting conditions. The feed per edge and the
axial depth of the cut was getting as the critical factors for the
ductile–brittle transition in micro cutting of glass by milling
process [23]
III. RESULTS & OBSERVATIONS
The Bar Chart Shows that numbers of paper published with
respect to their Machining process. The Pie Chart shows that
percentage of research conducted in different machining
process on glass material & its output results

I. Ultra precision Machining

This paper presents a specific cutting-energy based model
to predict the ductile–brittle transition point in ultra-precision
machining of brittle materials. The energy produced in brittle
and ductile modes of machining is modeled as a function of
work-material intrinsic properties, tool geometry and process
parameters. The developed model is validated by single-edge
cutting tests on single-crystal silicon and BK7 glass [24]. The
author found the different material removal mechanisms
involved in the machining of brittle materials & due to reason
of Free abrasive machined surfaces of materials indicate that
the material removal occurs due to micro indentations by the
abrasive particles, which cause lateral cracking [29]

J. Vibration-Assisted Machining(VAM)
In this paper authors developed the specific cutting energy
based model is with VAM by taking vibration parameters in Fig 1 Distribution of the collected research papers for
addition to the work-material intrinsic properties, tool machining on Glass Material.
geometry and machining parameters for that single crystal
silicon taking as work-piece and single crystal diamond used
as tool Material [37]

K. Atmospheric Pressure Plasma Jet (APPJ)

This paper shows the development of an APPJ chemical
machining process for defect free and high efficiency

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Volume – 5 Special Issue – I February 2015 ISSN NO: 0976-2558

3.This review shows that development of machining process

Fig.2.Percentage of Research conducted in different
machining process on glass
Fig.3. Percentage of research focused on different types of
results on Glass
CONCLUSION
1.The review shows that most of machining process is used
machined to glass material by Laser,USM,ECDM,AWJM,
MAJM process.
2. The researchers found out mostly MRR, Ra, Surface
quality,Features or profile surface quality and Depth of
cut/micro hole are output results.
on glass material from past to present state.
ACKNOWLEDGMENT
The author gratefully acknowledge the help provide to guiding
this research paper by Dr. Raj Ballav & Dr. Amaresh Kumar
Department of Manufacturing Engineering, National Institute
of Technology, Jamshedpur.
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