Nanometer-Scale, Ductile-Mode Cutting of Soda-Lime Glass

In this study, grooving and cutting tests were carried out to evaluate cutting performance of soda-lime glass using an ultra-precision lathe with a single-crystal diamond tool. The machined workpiece surface topography, chip formation, and surface roughness were examined using SEM and AFM. Tool wear was measured using a Nomarski microscope. Experimental results indicate that with the depth of cut increasing, there is a ductile-brittle transition in cutting of soda-lime glass materials. Under different cutting conditions, two types of surfaces are achieved: ductile cutting surface and fractured surface. Chips always formed in an irregular and discontinuous shape. Cutting modes have a significant effect on the machined workpiece surface roughness. Tool wear mainly occurs on the flank face and its wear mechanism is dominated by abrasion. Ductile cutting can be achieved when the undeformed chip thickness is less than a critical value.