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ABRASIVE MACHINING OF GLASS-INFILTRATED ALUMINA WITH DIAMOND BURS

The abrasive machining characteristics of a glass-infiltrated alumina used for fabrication of all-ceramic dental crowns were investigated using a high-speed dental handpiece and diamond burs with different grit sizes. The material removal rate, surface roughness, and extent of edge chipping were measured as a function of grit size. The removal rate decreased substantially with decreasing bur grit size from supercoarse (180 μm) to fine (40 μm) and ultrafine (10 μm). The removal rate with the supercoarse burs was approximately twice that achieved with the fine burs and four times the removal rate with the ultrafine burs. Both surface roughness and edge chipping damage were sensitive to diamond grit size. Chipping damage was severe and the surface roughness substantial with the supercoarse burs, while negligible edge chipping and smooth surfaces were obtained with the ultrafine burs. The removal rate also decreased with continued machining for all grit sizes. The observed reduction in removal rate was found to be primarily due to wear of the diamond grit and accumulation of debris on the bur (i.e., bur loading). After prolonged use, a significant loss of diamond grit was observed that led to a substantial loss of cutting efficiency. It is concluded that, with respect to material removal rate and surface integrity, diamond machining is a feasible machining process for glass-infiltrated alumina in the final infiltrated state. However, caution should be exercised in the use of diamond grit larger than 40 μm. Such burs may result in excessively rough surfaces, chipped edges, and strength limiting surface and subsurface microcracks.