Glass precision micro-cutting using spark assisted chemical engraving

Manufacturing industry faces new challenges with the emergence of need for production small batches personalized parts. Such methods demand a capability to integrate multiple machining operations in one manufacturing process reduce setup and calibration time tooling costs. This requirement is especially challenging difficult-to-machine materials such as glass, since there exist only limited number glass technologies further these often require specialized tooling. Glass cutting among crucial operations, which frequently required products. The presented study discusses free-form micro-cutting by Spark Assisted Chemical Engraving (SACE), determining cut parameters, terms tool feed-rate F depth-of-cut p function voltage. A simple model discussed allowing predict maximal product F⋅p can be used SACE. data allow time-consuming trial error appropriate parameters. An interesting finding that lowest times achieved tools 100-μm diameter. Cut surface roughness initial cuts reduced deploying subsequently incremental finishing (polishing) passes performed at lower voltage, feed rates higher angular rotation. It demonstrated very smooth surfaces (Rz ~ 1 μm) achieved.