Design and Fabrication of An Automated Glass Bottle Cutter for Reuse and Recycling Bottle Glass Products
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-03-16 |
| Journal | Journal of Engineering Technology and Applied Physics |
| Authors | Anuar Ishak, Ainaa Maya Munira Ismail, Ahmad Idzwan Yusuf, Ab Aziz Mohd Yusof |
| Institutions | Universiti Teknologi MARA |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Automated Diamond Glass Cutter
Section titled âTechnical Documentation & Analysis: Automated Diamond Glass CutterâThis document analyzes the requirements for the automated glass bottle cutter prototype, focusing on the critical diamond tooling component, and aligns these needs with 6CCVDâs advanced MPCVD diamond solutions.
Executive Summary
Section titled âExecutive SummaryâThe research details the successful design and fabrication of an automated glass bottle cutter utilizing a diamond blade, presenting a significant commercial opportunity in the recycling sector. 6CCVDâs expertise in high-performance MPCVD diamond materials is essential for optimizing tool life and cut quality in this application.
- Core Value Proposition: The prototype replaces manual scoring with a high-speed diamond blade, achieving rapid cutting (30-60 seconds) and superior edge finish.
- Critical Component: The system relies on a robust diamond blade (up to 120 mm diameter) operating at high RPM (up to 5000 RPM) to ensure efficiency and durability.
- Material Requirement: The application demands industrial-grade diamond tooling capable of withstanding high mechanical stress and thermal load, directly aligning with 6CCVDâs Polycrystalline Diamond (PCD) capabilities.
- Performance Enhancement: The paper identifies the need for integrated polishing and coolant application; 6CCVD offers ultra-low roughness polishing (Ra < 5 nm) to meet these requirements.
- Structural Integrity: Finite Element Analysis (FEA) confirmed the structural robustness of the carbon steel components, but the diamond tool itself must maintain integrity under high rotational speed and cutting forces.
- 6CCVD Solution: We provide custom-dimension PCD wafers (up to 125 mm) suitable for manufacturing the required high-performance cutting blades and associated polishing components.
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points extracted from the research define the operational parameters for the required diamond cutting tool and system.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Cutting Tool Type | Diamond Blade | N/A | Replaces conventional wheel cutters |
| Max Blade Diameter | 120 | mm | Maximum size accommodated by the design |
| Motor Speed (High) | 5000 | RPM | Recommended for thicker glass to ensure smooth cuts |
| Motor Speed (Low) | 3000 | RPM | Recommended for thinner/delicate materials to prevent cracking |
| Cutting Time | 30-60 | seconds | Time required per bottle, dependent on material thickness |
| Bottle Diameter Range | 3 to 10 | cm | Range of bottles the machine can accommodate |
| Prototype Power Output | 1.51 | kW | Total power output for the system |
| Max Von Mises Stress | 7.94 x 107 | N/m2 | Stress recorded on the blade holder component |
| Required Finish Enhancement | Polishing mechanism | N/A | Suggested upgrade for smoother edges |
Key Methodologies
Section titled âKey MethodologiesâThe prototype development and fabrication process highlight the need for precision engineering and robust material selection, particularly for the diamond tooling.
- Design and Simulation: The prototype was designed using SOLIDWORKS 2017, incorporating Finite Element Analysis (FEA) to validate the structural integrity of components (e.g., blade holder).
- Material Selection: Plain carbon steel (AISI 1013) was chosen for the structural components due to its ductility and suitability for machining and welding.
- Tool Integration: A DC motor was integrated to drive the diamond blade, enabling automated rotation and cutting, replacing manual scoring methods.
- Speed Control Implementation: The system incorporates two speed ranges (3000 RPM and 5000 RPM) to optimize cutting performance based on glass thickness, minimizing cracking and ensuring precision.
- Testing and Validation: The machine was successfully tested on various glass bottle diameters (50 mm and 70 mm) to confirm the ability to cut through and smooth the cut surface.
- Future Enhancements: Potential upgrades include integrating a coolant system to inhibit glass dust dispersion and adding a polishing mechanism for superior edge quality.
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & Capabilitiesâ6CCVD is uniquely positioned to supply the high-quality MPCVD diamond materials necessary to industrialize and enhance this automated glass cutting technology, ensuring maximum tool life and superior surface finish.
Applicable Materials
Section titled âApplicable MaterialsâTo achieve the required high-speed cutting efficiency (up to 5000 RPM) and long tool life necessary for commercial recycling operations, the following 6CCVD materials are recommended:
- Polycrystalline Diamond (PCD): Ideal for the primary cutting blade. PCD offers exceptional toughness, high wear resistance, and thermal stability, making it the standard choice for large-diameter industrial cutting and grinding wheels.
- Optical Grade Single Crystal Diamond (SCD): Recommended for any integrated polishing mechanism (as suggested in the paperâs enhancements). SCD can be fabricated into micro-polishing tools or pads, offering ultra-precise material removal for achieving the smoothest possible edge finish (Ra < 1 nm).
Customization Potential
Section titled âCustomization PotentialâThe research requires a diamond blade up to 120 mm in diameter. 6CCVDâs manufacturing capabilities directly address this need:
| Prototype Requirement | 6CCVD Capability | Benefit to Research |
|---|---|---|
| Blade Diameter (Max 120 mm) | Custom PCD plates/wafers up to 125 mm | Enables fabrication of full-size, single-piece diamond cutting wheels. |
| Polishing Mechanism | Polishing to Ra < 5 nm (PCD) or Ra < 1 nm (SCD) | Achieves the âsmoother edgesâ enhancement identified in the abstract. |
| Tool Mounting/Integration | Custom Metalization (Au, Pt, Ti, W, Cu) | Allows for robust bonding of the diamond blade to the carbon steel motor mount and improved thermal management. |
| Thickness Requirements | SCD/PCD thickness from 0.1 ”m to 500 ”m | Provides flexibility in designing the optimal blade geometry and thickness for various glass types. |
Engineering Support
Section titled âEngineering Supportâ6CCVDâs in-house PhD team specializes in optimizing diamond material properties for extreme mechanical and thermal applications. We can assist with material selection for similar High-Speed Diamond Machining and Glass Processing projects, specifically focusing on:
- Wear Rate Optimization: Selecting the optimal PCD grain size and binder material to maximize tool life at 5000 RPM.
- Thermal Management: Designing diamond tooling geometry and metalization layers to efficiently dissipate heat generated during high-speed cutting, crucial given the paperâs suggestion for integrating a coolant.
- Surface Finish Improvement: Consulting on the design and integration of secondary SCD or PCD polishing components to achieve commercial-grade edge quality.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
The glass bottle cutter has a substantial commercialisation potential, as present trends indicate a growing interest in repurposing waste materials. This apparatus enables communities to manufacture new items from discarded glass bottles, including drinking glasses, ashtrays, and vases. Disposal at recycling centres or craft stores is essential for businesses such as restaurants and bars that often produce excess glass waste. Hence, this apparatus is resilient and long-lasting, designed to handle significantly larger amounts more efficiently than manual glass bottle cutters, which require scoring the bottle and alternating between hot and cold water. The main goals of this project are to develop a prototype for a glass bottle-cutting machine and to manufacture the machine according to the designed prototype. The manufacturing process encompasses measuring, cutting, welding, and drilling, with the machine predominantly constructed from metals. It employs a DC motor to facilitate the rotation of the diamond blade, substituting conventional wheel cutters. This design markedly diminishes the necessity for physical labour and enables bottles to be severed in under one minute. The cutter accelerates the procedure, yielding a superior finish with reduced physical exertion. The design and analysis of the prototype have been successful. Potential enhancements may involve the integration of a safety button, applying a coolant to inhibit the dispersion of glass dust, and including a polishing mechanism for smoother edges. These upgrades would boost the machineâs efficiency and desirability.