Macor Machinability
Macor machinable glass-ceramic is a special material that can be machined using common metal tools, which is a major highlight and makes it the first choice for high-precision parts.
Matrix: It is composed of glass components such as silicon dioxide and boron oxide, which provides good plasticity.
Crystalline phase: It contains mica crystals, which are evenly distributed in layers. This structure can provide mechanical strength and can be finely processed by cutting and slight peeling.
Microscopic behavior during processing
Crack extension inhibition: During the processing, the cleavage characteristics of mica crystals localize crack extension and reduce the risk of overall failure.
Thermal stress distribution: The presence of glass phase can absorb heat to a certain extent, but excessive processing temperature may still cause local softening and affect precision.
Machining Preparation
Spindle speed
Use a lower speed to reduce heat build-up and avoid material breakage
Clamping method
Use soft jaws to grip workpieces to distribute loads and reduce stress concentrations
Coolant
Using coolants specially formulated for glass or ceramic materials is recommended to extend tool life and improve machining quality.
Macor Machining Parameters
1.Turning
- • Spindle speed: 1500-3000 rpm (depending on cutting depth and tool material)
- • Feed rate: 0.01-0.05 mm/rev. It is recommended to start at a low speed and gradually optimize.
- • Cutting depth: No more than 0.5 mm per cut to avoid material stress concentration
Recommended tools：
- • Diamond coated tools: suitable for continuous cutting
- • PCD (polycrystalline diamond) tools: for machining with high precision requirements.
2.Drilling
- • Speed: 800-1500 rpm, adjusted according to the hole size.
- • Cooling method: circulating water cooling system to avoid local overheating.
- • Backboard support: prevent the hole outlet from cracking.
- • Drill bit material: use microcrystalline diamond coated drill bits to extend service life.
3.Milling
- • Tool path optimization: Use spiral cutting method to avoid impact on the workpiece due to emergency stop.
- • Spindle speed: 3000-5000 rpm, suitable for processing with high surface finish requirements
- • Cutting fluid: Use emulsion with a concentration of 5-8%
4.Polishing process
- • Rough polishing: polishing with 400-grit silicon carbide sandpape
- • Fine polishing: using 1-micron aluminum oxide or cerium oxide suspension, and achieving high flatness through a slow-speed rotating polishing disc
Appendix
Process technology innovation
Ultrasonic Assisted Machining (UAM)
Using ultrasonic vibration to reduce cutting force and improve machining efficiency by 20%-40%, it is especially suitable for machining complex geometric structures.
Multi-station fixture and flexible manufacturing
Multi-station fixtures can be used to process multiple workpieces in one clamping, saving clamping time.
Introducing flexible manufacturing systems (FMS) to achieve multi-process integration and improve overall efficiency.
Advanced software optimization
Use the path optimization function of CAM software to design the shortest cutting path, reduce tool idle travel and repeated processing.
Simulate and analyze the processing process to avoid unnecessary trial and error
Problems in macor machining
Problems of workpiece fragmentation in macor machining
Cause: Cutting parameters are too high or clamping force is too large.
Solution: Reduce cutting speed and recalibrate the clamping device.
Machining tool life issues
Cause: High material hardness and accumulated cutting heat.
Solution: Use diamond-coated tools and ensure sufficient coolant flow
High surface roughness
Cause: The tool is not sharp or the feed rate is too fast.
Solution: Replace the tool with a new one and adjust the feed rate to 0.02-0.05 mm/rev.
Contact Us
Macor is a very flexible technical ceramic, but its processing requires a combination of scientific craftsmanship and rigor. By optimizing cutting parameters, selecting appropriate tools, and strictly controlling the processing environment, processing efficiency can be significantly improved and ideal surface quality can be obtained. If you require custom processing services or further technical support, please feel free to contact our team. We will provide you with the best solution with our professional knowledge and rich experience.
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