ArticleMaterials (Basel, Switzerland)2026
PFC Simulation and Experimental Investigation of Crack Evolution and Surface Morphology in Rehbinder-Effect-Assisted Longitudinal-Torsional Ultrasonic Vibration Milling of Borosilicate Glass.
Article in Materials (Basel, Switzerland), 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
Borosilicate glass is widely used in microfluidic chips, optical components, and precision devices, but it is susceptible to cracking and subsurface damage during machining because of its high hardness and brittleness. Longitudinal-torsional ultrasonic vibration-assisted milling (LTUVAM) can improve material removal stability, whereas the Rehbinder effect can reduce surface energy and weaken local material resistance. In this study, the additional effect of a Rehbinder-active medium under LTUVAM conditions was investigated to reduce crack-related surface damage and improve surface integrity. First, a two-dimensional cutting model of borosilicate glass was established using Particle Flow Code in two dimensions (PFC2D) to simulate crack initiation and propagation under conventional milling (CM) and LTUVAM conditions. The simulation results show that ultrasonic vibration promoted finer and more distributed microcracks and reduced the development of large-scale fractures, thereby modifying the brittle material removal behavior. Subsequently, milling experiments were conducted under LTUVAM conditions with a Rehbinder-active medium supplied to the cutting zone. Compared with LTUVAM without the solution, the proposed process significantly reduced surface roughness, with maximum reductions of 40.7% in
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