Simulation-Assisted Comparative Process Planning for Machining of Quartz Sintered Materials

This study presents a simulation-assisted engineering framework intended to support comparative machining parameter selection for quartz sintered materials. The approach integrates CAD/CAM-based analysis, an illustrative Design of Experiments (DOE) framework, and preliminary experimental validation to improve process planning and machining quality. The analysis focuses on key technological parameters, including cutting speed (vc), feed rate (f), and depth of cut (ap), evaluated across cutting, milling, and finishing stages. The results indicate that feed rate is the dominant parameter influencing process stability, surface quality, and edge integrity. A practical transition region of approximately 1200 mm/min was identified, above which increased vibration, defect formation, and surface degradation occur. The complementary DOE analysis confirms the relative importance of process parameters and reveals interaction effects, particularly between feed rate and depth of cut, which significantly influence defect formation under high-load conditions. Preliminary industrial observations provide trend-oriented support for the simulation-predicted process behavior. Based on the integrated analysis, a preliminary technological operating region was identified (vc = 1080–1320 m/min, f = 800–1200 mm/min, ap = 0.5–1.0 mm), suggesting a practical compromise between machining efficiency and surface integrity. The proposed methodology provides preliminary engineering support for comparative process planning and defect-reduction-oriented parameter selection in the machining of brittle materials. The novelty of this work lies in the integration of CAD/CAM simulation, DOE-based interaction analysis, and experimental validation for supporting the identification of a practical technological operating region for machining brittle materials. The presented results should therefore be interpreted as engineering-oriented comparative process-planning guidelines rather than statistically generalized machining laws. The presented study should be interpreted as an exploratory simulation-assisted engineering investigation intended to support comparative process planning rather than as a fully experimentally validated machining model.