Surface roughness and subsurface damage relationship in BK7G18 optical glass grinding: A combined theoretical and experimental study
MATERIALS TODAY COMMUNICATIONS, cilt.53, ss.115437, 2026 (SCI-Expanded, Scopus)
- Yayın Türü: Makale / Tam Makale
- Cilt numarası: 53
- Basım Tarihi: 2026
- Doi Numarası: 10.1016/j.mtcomm.2026.115437
- Dergi Adı: MATERIALS TODAY COMMUNICATIONS
- Derginin Tarandığı İndeksler: Scopus, Science Citation Index Expanded (SCI-EXPANDED), Chemical Abstracts Core, Compendex, INSPEC
- Sayfa Sayıları: ss.115437
- Gazi Üniversitesi Adresli: Evet
Özet
Surface roughness (SR) and subsurface damage (SSD) are key indicators that influence optical properties, mechanical strength, and long-term reliability during the grinding of brittle materials to achieve high surface quality. In the present study, theoretical and experimental investigations were conducted to establish a quantitative force-based relationship between SR and SSD during the grinding of BK7G18 optical glass. A full factorial design of experiment (DOE) was used to study a pair of resin-bonded diamond grinding wheels, with spindle speed and depth of cut as grinding parameters. Surface integrity was assessed through profilometry measurements, and subsurface crack morphology was analyzed through scanning electron microscopy (SEM). Grinding forces were simultaneously measured, which enabled a force-based explanation of subsurface crack formation in terms of fracture mechanics. The findings reveal a nonlinear power-law relationship between SR and SSD with weak sensitivity, which is essentially dominated by the grinding normal force, providing a force-based macro–micro-scale connection for quantitative nondestructive estimation of SSD when SR is interpreted within a force-based mechanical framework. The approach provides a physically meaningful predictive model that correlates observable surface characteristics with subsurface fracture development. The results also show that using a fine-grit resin-bonded diamond wheel, moderate-to-high spindle speed, and shallow depths of cut can effectively reduce SR and SSD, providing a basis for understanding these mechanisms and serving as a reference for controlling surface quality in precision optical-glass grinding.