This study simulates the sawing process with an abrasive circular saw blade and analyzes the generation of cutoff surfaces in the sawing process with the consideration of the blade deflection caused by the asymmetric wear of the blade outer edge. The analysis is built on the previous work of Matsui (1956, J. Jpn. Soc. Precis. Eng., 22, pp. 477–481) who presented an analytical formula for cutting force acting on a conical cutting edge. In this paper, the Matsui formula is modified to take into account the “size effect” of grinding and used to calculate the grinding force acting on the blade surface. A differential equation is constructed, and the related numerical solutions are provided to describe the blade deflection behavior in the sawing process. The study then discusses the influences of the “size effect,” workpiece length, workpiece speed and feed rate, as well as cutting edge density on sawing accuracies. Also discussed are workpiece speed and cutting edge density on the maximum deviation of the cutoff surface.
Issue Section:
Research Papers
1.
Illy
, E. K.
, Knowles
, M.
, Gu
, E.
, and Dawson
, M. D.
, 2005, “Impact of Laser Scribing for Efficient Device Separation of LED Components
,” Appl. Surf. Sci.
0169-4332, 249
, pp. 354
–361
.2.
Gu
, E.
, Jeon
, C. W.
, Choi
, H. W.
, Rice
, G.
, Dawson
, M. D.
, Illy
, E. K.
, and Knowles
, M. R. H.
, 2004, “Micromachining and Dicing of Sapphire, Gallium Nitride and Micro LED Devices With UV Copper Vapor Laser
,” Thin Solid Films
0040-6090, 453–454
, pp. 462
–466
.3.
Perrottet
, D.
, Boillat
, C.
, Amorosi
, S.
, and Richerzhagen
, B.
, 2005, “PV Processing: Improved PV-Cell Scribing Using Water Jet Guided Laser
,” Refocus
1471-0846, 6
, pp. 36
–37
.4.
Richerzhagen
, B.
, Perrottet
, D.
, and Kozuki
, Y.
, 2005, “Dicing of Wafers by Patented Water-Jet-Guided Laser: The Total Damage-Free Cut
,” JLPS 2005, Tokyo.5.
Perrottet
, D.
, Mai
, T. A.
, and Richerzhagen
, B.
, 2005, “Damage-Free Wafer Dicing Using the Water Jet Guided Laser Technology
,” Micro Systems Technologies 2005, Munich.6.
Perrottet
, D.
, Spiegel
, A.
, Amorosi
, S.
, and Richerzhagen
, B.
, 2005, “GaAs-Wafer Dicing Using the Water Jet Guided Laser
,” CS Mantech 2005, New Orleans.7.
Sibailly
, O.
, and Richerzhagen
, B.
, 2004, “Laser Dicing of Silicon and Composite Semiconductor Materials
,” Photonics West 2004, San Jose.8.
Luo
, S. Y.
, Tsai
, Y. Y.
, and Chen
, C. H.
, 2006, “Studies on Cut-Off Grinding of BK7 Optical Glass Using Thin Diamond Wheels
,” J. Mater. Process. Technol.
0924-0136, 173
, pp. 321
–329
.9.
Mizuno
, M.
, Iyama
, T.
, Mori
, Y.
, and Wajima
, N.
, 2001, “Effect of Rotational Frequency of OD-Blade on its Warp
,” Trans. Jpn. Soc. Mech. Eng., Ser. C
0387-5024, 67
(C654
), pp. 559
–564
(in Japanese).10.
Jerro
, H. D.
, Pang
, S. S.
, Yang
, C.
, and Mirshams
, R. A.
, 1999, “Kinematics Analysis of the Chipping Process Using the Circular Diamond Saw Blade
,” ASME J. Manuf. Sci. Eng.
1087-1357, 121
(2
), pp. 257
–262
.11.
Mizuno
, M.
, Iyama
, T.
, Shinomiya
, K.
, and Mori
, Y.
, 1999, “Effect of Centrifugal Force on the Edge Compliance of OD-Blade
,” Trans. Jpn. Soc. Mech. Eng., Ser. C
0387-5024, 65
(C640
), pp. 4909
–1999
(in Japanese).12.
Jerro
, H. D.
, Pang
, S. S.
, Yang
, C.
, and Mirshams
, R. A.
, 1998, “Grit Distribution in Superabrasive Diamond Sawing
,” Int. J. Adv. Manuf. Syst. (IJMAS), Spec Issue Decis. Eng.
1536-2647, 1
(1
), pp. 25
–38
.13.
Ohbuchi
, Y.
, Ueda
, N.
, Touge
, M.
, Matsuo
, T.
, Takeuchi
, K.
, and Hata
, S.
, 1997, “High Precision Cut-Off Grinding of Electronic Ceramics With Thin Diamond Wheel
,” International Conference on Precision Engineering, Taiwan, pp. 391
–395
.14.
Miwa
, T.
, and Inasaki
, I.
, 1997, “Blade Wear and Wafer Chipping in Dicing Process
,” International Conference on Precision Engineering, Taiwan, pp. 397
–402
.15.
Mizuno
, M.
, Iyama
, T.
, Yoshida
, H.
, and Tamaki
, J.
, 1997, “High-Precision Slicing With OD-Blade: Effect of Flange Size on Blade Deformation
,” J. Soc. Grind. Eng.
, 42
, pp. 338
–343
(in Japanese).16.
Mizuno
, M.
, Iyama
, T.
, Yoshida
, H.
, and Tamaki
, J.
, 1997, “Theoretical Analysis of OD-Blade Behavior in High-Precision Slicing: Effect of Inner Cross-Section Shape of Abrasive Layer on Cutoff Accuracy
,” J. Soc. Grind. Eng.
, 41
, pp. 225
–230
(in Japanese).17.
Mizuno
, M.
, Iyama
, T.
, Kuriyagawa
, T.
, Oka
, M.
, and Suzuki
, N.
, 1994, “Theoretical Analysis of Blade Behavior in Outer-Blade Slicing: Effect of Side Relief Angle of Blade
,” Trans. Jpn. Soc. Mech. Eng., Ser. C
0387-5024, 60
(C580
), pp. 4368
–4373
(in Japanese).18.
Mizuno
, M.
, Iyama
, T.
, Takada
, M.
, Oka
, M.
, and Suzuki
, N.
, 1994, “Analysis of Blade Behavior in Outer-Blade Slicing
,” Trans. Jpn. Soc. Mech. Eng., Ser. C
0387-5024, 60
(C569
), pp. 314
–319
(in Japanese).19.
Mizuno
, M.
, Shoji
, K.
, Iyama
, T.
, and Mori
, Y.
, 1993, “Numerical Analysis of Cut-Off Surface Geometry in Outer-Blade Slicing
,” J. Soc. Grind. Eng.
, 37
, pp. 90
–95
(in Japanese).20.
Mizuno
, M.
, Shoji
, K.
, Iyama
, T.
, and Mori
, Y.
, 1992, “Generating Mechanism of Cut-Off Surfaces in Outer-Blade Slicing
,” J. Soc. Precis. Eng.
0912-0289, 58
, pp. 105
–110
(in Japanese).21.
Yamasaka
, M.
, Fujisawa
, M.
, Oku
, T.
, and Masuda
, M.
, 1990, “Improvement of Straightness in Precision Cut-Off Grinding Using Thin Diamond Wheels
,” CIRP Ann.
0007-8506, 39
(1
), pp. 333
–336
.22.
Shoji
, K.
, Mizuno
, M.
, Iyama
, T.
, and Mori
, Y.
, 1990, “Studies on Outer-Blade Slicing, 3rd Report: Analytical Formulas for Slicing Force
,” J. Soc. Precis. Eng.
0912-0289, 56
, pp. 1493
–1499
(in Japanese).23.
Shoji
, K.
, and Mizuno
, M.
, 1989, “Studies on Outer-Blade Slicing, 2nd Report: Deformation of Slicing Blade
,” J. Soc. Precis. Eng.
0912-0289, 55
, pp. 1886
–1892
(in Japanese).24.
Matsui
, S.
, 1956, “Studies on Flat Superfinishing, Part 3: On Flat Superfinishing Resistance
,” J. Jpn. Soc. Precis. Eng.
0374-3543, 22
, pp. 477
–481
(in Japanese).25.
Liao
, T. W.
, Li
, K.
, and McSpadden
, Jr., S. B.
, 2000, “Wear Mechanisms of Diamond Abrasives During Transition and Steady Stages in Creep-Feed Grinding of Structural Ceramics
,” Wear
0043-1648, 242
, pp. 28
–37
.26.
Wang
, H.
, and Subhash
, G.
, 2002, “Mechanics of Mixed-Mode Ductile Material Removal with a Conical Tool and the Size Dependence of the Specific Energy
,” J. Mech. Phys. Solids
0022-5096, 50
, pp. 1269
–1296
.27.
Hwang
, T. W.
, Evans
, C. J.
, and Malkin
, S.
, 1999, “Size Effect for Specific Energy in Grinding of Silicon Nitride
,” Wear
0043-1648, 225–229
, pp. 862
–867
.28.
Shaw
, M. C.
, 1996, “Principles of Abrasive Processing
,” Oxford University Press
, London.29.
Azarkhin
, A.
, and Devenpeck
, M. L.
, 1997, “Enhanced Model of a Plowing Asperity
,” Wear
0043-1648, 206
, pp. 147
–155
.30.
Abebe
, M.
, and Appl
, F. C.
, 1988, “Theoretical Analysis of the Basic Mechanics of Abrasive Processes: Part I. General Model
,” Wear
0043-1648, 126
, pp. 251
–266
.31.
Torrance
, A. A.
, 1987, “An Approximate Model of Abrasive Cutting
,” Wear
0043-1648, 118
, pp. 217
–232
.32.
Abildgaard
, T.
, 1984, “Prediction of the Force Components Acting on a Ploughing Cone by Means of Three-Dimensional Upper Bound Theory
,” Advanced Technology of Plasticity
, Proc. Int. Conf. on Tech. of Plasticity
, Tokyo, Vol. 1
, pp. 121
–126
.33.
Avitzur
, B.
, Huang
, C. K.
, and Zhu
, Y. D.
, 1984, “A Friction Model Based on the Upper-Bound Approach to the Ridge and Sublayer Deformations
,” Wear
0043-1648, 95
, pp. 59
–77
.34.
Challen
, J. M.
, Oxley
, P. L. B.
, and Doyle
, E. D.
, 1983, “The Effect of Strain Hardening on the Critical Angle for Abrasive (Chip Formation) Wear
,” Wear
0043-1648, 88
, pp. 1
–12
.35.
Gilormini
, P.
, and Felder
, E.
, 1983, “Theoretical and Experimental Study of the Ploughing of a Rigid-Plastic Semi-Infinite Body by a Rigid Pyramidal Indenter
,” Wear
0043-1648, 88
, pp. 195
–206
.36.
Torrance
, A. A.
, 1981, “A New Approach to the Mechanics of Abrasion
,” Wear
0043-1648, 67
, pp. 233
–257
.37.
Vathaire
, M. De
, Delamare
, F.
, and Felder
, E.
, 1981, “An Upper Bound Model of Ploughing by a Pyramidal Indenter
,” Wear
0043-1648, 66
, pp. 55
–64
.38.
Challen
, J. M.
, and Oxley
, P. L. B.
, 1979, “An Explanation of the Different Regimes of Friction and Wear Using Asperity Deformation Models
,” Wear
0043-1648, 53
, pp. 229
–243
.39.
Sin
, H.
, Saka
, N.
, and Suh
, N. P.
, 1979, “Abrasive Wear Mechanisms and the Grit Size Effect
,” Wear
0043-1648, 55
, pp. 163
–190
.40.
Tsukizoe
, T.
, and Sakamoto
, T.
, 1975, “Friction in Scratching Without Metal Transfer
,” Bull. JSME
0021-3764, 18
, pp. 65
–72
.41.
Brecker
, J. N.
, and Shaw
, M. C.
, 1974, “Specific Energy in Single Point Grinding
,” CIRP Ann.
0007-8506, 23
, pp. 93
–94
.42.
Hisakado
, T.
, 1970, “On the Mechanism of Contact Between Solid Surfaces
,” Bull. JSME
0021-3764, 13
, pp. 129
–139
.43.
Childs
, T. H. C.
, 1970, “The Sliding of Rigid Cones Over Metals in High Adhesion Conditions
,” Int. J. Mech. Sci.
0020-7403, 12
, pp. 393
–403
.44.
Sedriks
, A. J.
, and Mulhearn
, T. O.
, 1964, “The Effect of Work-Hardening on the Mechanics of Cutting in Simulated Abrasive Processes
,” Wear
0043-1648, 7
, pp. 451
–459
.45.
Sedriks
, A. J.
, and Mulhearn
, T. O.
, 1963, “Mechanics of Cutting and Rubbing in Simulated Abrasive Processes
,” Wear
0043-1648, 6
, pp. 457
–466
.46.
Goddard
, J.
, and Wilman
, H.
, 1962, “A Theory of Friction and Wear During the Abrasion of Metals
,” Wear
0043-1648, 5
, pp. 114
–135
.47.
Mulhearn
, T. O.
, and Samuels
, L. E.
, 1962, “The Abrasion of Metals: A Model of the Process
,” Wear
0043-1648, 5
, pp. 478
–498
.48.
Matsui
, S.
, and Shoji
, K.
, 1969, “Estimation of Wear Process of Grinding Wheels
,” J. Jpn. Soc. Precis. Eng.
0374-3543, 35
, pp. 235
–240
(in Japanese).49.
Benson
, R. C.
, and Bogy
, D. B.
, 1978, “Deflection of a Very Flexible Spinning Disk Due to a Stationary Transverse Load
,” ASME J. Appl. Mech.
0021-8936, 45
, pp. 636
–642
.50.
Iwan
, W. D.
, and Moeller
, T. L.
, 1976, “The Stability of a Spinning Elastic Disk With a Transverse Load System
,” ASME J. Appl. Mech.
0021-8936, 43
, pp. 485
–490
.51.
Chonan
, S.
, and Hayase
, T.
, 1987, “Stress Analysys of a Spinning Annular Disk to a Stationary Distributed, In-Plane Edge Load
,” ASME J. Vib., Acoust., Stress, Reliab. Des.
0739-3717, 109
, pp. 277
–282
.52.
Timoshenko
, S.
, and Krieger
, W.
, 1959, Theory of Plates and Shells
, 2nd ed., McGraw-Hill
, New York.Copyright © 2008
by American Society of Mechanical Engineers
You do not currently have access to this content.
