Maximizing production throughput of high-quality microchannels in borosilicate glass using thermochemically assisted grinding with force-feedback control

The creation of high-precision channels and pockets in hard and brittle materials such as glass and technical ceramics is a challenge in academia and industry. The simultaneous application of electrochemical discharges and mechanical grinding to a workpiece has been shown in the past to improve productivity and surface quality in these materials, in a process named grinding-aided Electrochemical Discharge Machining . However, these methods still suffer from variability in material removal rates and limited process control. The present study aims to maximize productivity using this process while preserving adequate surface quality by proposing a novel force-feedback algorithm aiming to maintain a constant machining force during the entire precision machining process. This study introduces a novel force-feedback strategy based on a proportional–integral–derivative algorithm to maintain a constant machining force in the thermochemically assisted grinding process. The approach adjusts tool feed rate in response to real-time force measurements, improving repeatability and increasing throughput. Experiments were conducted on borosilicate glass using an 800 µm diameter diamond grinding tool, varying force and voltage. Results show that force-feedback control stabilizes machining conditions, enabling predictable feed rates and improved surface integrity. Analysis reveals two distinct removal regimes, thermochemical-ductile and brittle, depending on feed rate and thermal interaction. The proposed method provides actionable insights for selecting force and voltage parameters to balance productivity and quality, laying the groundwork for reliable, high-performance micromachining of brittle materials.