Experimental Study and Simulation On Microwave Drilling of Metals and Glasses

Journal of Experimental & Applied Mechanics
ISSN: 2230-9845
Volume 5, Issue 1
www.stmjournals.com
Experimental Study and Simulation on Microwave

Drilling of Metals and Glasses
Titto John George1*, Apurbba Kumar Sharma2, Pradeep Kumar2
1
Department of Mechanical Engineering, Viswajyothi College of Engineering and Technology,

Muvattupuzha, Kerala, India
2
Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee, India
Abstract
Microwave heating is being developed to apply for a variety of engineering applications
in the last few years due to some special advantages of using microwave. This paper
presents a study on attempting microwave drilling of materials especially metals, as
metal processing with microwave was a difficult task due to reflection of microwaves by
metals at room temperature. A special fixture was developed to study the microwave
drilling on metals and non metals and tests were conducted on Aluminium, Copper, Mild
steel and Borosilicate glass inside a domestic microwave oven. Metals were drilled with
microwave hybrid heating and glass was drilled with plasma generated through
microwave. The specimens were characterised through SEM and simulations were done
on microwave heating of metals and glass in a similar environment to drilling.
Keywords: Microwaves, material processing, drilling, plasma, simulation

*Author for Correspondence E-mail: titto84886@gmail.com
INTRODUCTION
Microwaves are waves in the electromagnetic
spectrum with wavelength ranging from 1mm
to 1m and a frequency of 300 MHz to 300
GHz. Microwaves possess some special
properties which makes it useful for a variety
of engineering applications along with its use
in the communication devices. Microwaves
interact with materials at the molecular level
and transfer energy depending on the
properties of material like dielectric constant
and operating temperature. A schematic
diagram of microwave material interaction is
given in Figure 1. Some materials like glass
are transparent to microwave glass while some
others like metals are opaque which will
reflect microwave at room temperature.
Materials like charcoal will absorb microwave
and produce heat. Microwave heating has
some special characteristics like volumetric
heating, penetrating radiation, separate effect
of electric and magnetic field, variation with
temperature and phase change etc. These
special characteristics have inspired the
researchers to develop more and more
engineering applications of microwave
processing [1-3].
Fig. 1: Various Types of Microwave Material

Interaction.
Initially direct microwave heating was used in
most of the applications and later indirect or
microwave hybrid heating (MHH) was
developed to heat the materials which will not
readily absorb microwave at room temperature
but starts absorbing after a threshold
temperature. Later metals were used in
microwave processing in powder form because
metal powder absorbs microwave and get
heated up. Initially microwave was used in
sintering of metals and non metals, heating of
ores for extraction and for joining of non
metals as metals in bulk form reflect
microwave due to low skin depth. Later
microwaves were used in joining of bulk
metals, cladding and brazing by MHH and
plasma formation [4-10].
JoEAM (2014) 10-19 STM Journals 2014. All Rights Reserved
Page 10
Simulation on Microwave Drilling

George et al.
__________________________________________________________________________________________
HISTORY OF MICROWAVE
DRILLING
The special properties of microwave have
been made researchers to think in applying it
to machining process. Mechanical drills satisfy
most of the needs, but has some disadvantages
like loud noise during operation, vibrations,
dust, and are not always effective which the
microwave assisted drilling is trying to
overcome.
A method for drilling/cutting using microwave
discharge was suggested by Kozyrev et al
1996 [11]. Combined action of microwave
electric field and focused laser radiation on
dielectrics was studied to develop discharge
techniques for machining of certain kind of
ceramics. The concept was based on the
process of local absorption of microwave
power by dielectrics followed by its damage
due to intensive heating. Localization of
microwave absorption was made by heating a
small area using thermal pulse such as laser as
microwave will be absorbed more by ceramics
at high temperature. Application of microwave
field increased the volume of removed
material at least 8 times at 1 minute exposure
[11]. However, the profile was not good and
the complexity of set up was the hindrance in
conducting more of such studies.
A novel method for drilling hard nonconductive materials by concentration of the
microwave energy into a small spot of was
introduced by Jerby et al. [12, 13]. The near
field microwave radiator was constructed as a
coaxial waveguide ended with an extendable
monopole antenna, which functions also as the
drill bit with a movable centre conductor
sustaining high temperatures. The waveguide
was cooled through pressurised gas flow. The
microwave coming out through the tip of
antenna creates a hot spot on the material and
makes it soft or molten. The coaxial centre
electrode is then inserted into this molten hot
spot and shapes its boundaries. This
microwave drill was tested for drilling in a
variety of hard non-conductive dielectric
materials like concrete, alumina, glassceramics but not in metals due to reflection of
microwaves [12, 13].
This paper describes the experiments
performed to prove the possibility of
microwave drilling of metallic materials as it

was not possible by the previous researchers.
It also reports the formation of microwave
plasma at room temperature and atmospheric
pressure which is used for drilling of glass
which has never been attempted earlier. Both
the process was studied by computer
simulation of microwave heating.
EXPERIMENTAL FIXTURE
A schematic diagram of the experimental
fixture made of concrete, used for the trials is
shown in Figure 2. A spring of required
stiffness was fixed to the bolt at the top of
setup. The drill bit was fixed at the bottom end
of the spring as shown in the schematic
diagram. The spring and the drill bit were
covered by microwave friendly materials to
avoid reflection of microwave by metallic
materials. The specimen was placed at the
base of the setup and was covered at the top if
required. The fixture was made in such a way
that once the whole setup was put inside the
microwave cavity and power is switched on
the specimen becomes heated by microwave.
The drill bit attached to the spring will apply a
small force to the specimen which is in a
softened state due to heating. The preset force
was increased or decreased by adjusting the
height of the base plate on which specimen
was placed. Also, the strength of the beam
which is holding the spring should be
sufficient to withstand the spring force. All
experiments were performed at 2.45 GHz
frequency inside a multimode cavity of a
domestic microwave oven.
Fig. 2: Schematic Diagram of Experimental

Fixture for Microwave Drilling.
DRILLING OF METALS
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Volume 5, Issue 1, ISSN: 2230-9845
Some trials were conducted to study the

possibilities for drilling of metallic material
through MHH. It is known fact that bulk
metals reflect microwave at room temperature.
The heating of metals has been achieved by
using MHH technique by using a suitable
susceptor.
Experimental Procedure
The specimen was placed at the base of the set
up and was covered at the top by a concrete
plate and with graphite sheets as required to
prevent reflection of microwave by the metal
plate. The force was applied by lifting the
specimen above its position against the spring
pressure on tungsten rod which, in turn, will
apply force on the workpiece. The susceptor,
which was charcoal powder, was directly
placed above the workpiece where we want to
drill. Once the whole set up was put inside the
microwave cavity, the exposure was initiated
as per the parameters described in Table 1.
The red hot susceptor supplies heat to the
metal beneath it by conventional modes of
heat transfer, and at high temperature, metal
starts absorbing microwave. Once the metal
gets softened, the drill bit is pushed
downwards due to the force applied by the
spring and the hole is formed in the workpiece.
The experiments were performed with an Al
sheet of 1 mm thickness, Cu sheet of 1 mm
thickness and mild steel of thickness 1 mm.
The drill bit used was tungsten rod of 2 mm
for all cases. Also a stainless steel rod of 0.8
mm diameter was used for drilling another

aluminium specimen. All specimens were
exposed to microwave of frequency 2.45 GHz
in a multimode applicator with 900 W powers.
Temperature of the metal specimen was
measured by inserting a thermocouple rod
through a hole drilled at the top of the
microwave cavity. The end of the thermo
couple was touching the specimen at the edge.
The specimens were then cut along the drilled
hole using a Baincut low speed saw and then
polished with emery papers of fine grades and
alumina powder. Then it was etched with
proper acid solutions. Later the drilled
specimens were characterised in scanning
electron microscope (SEM).
Simulation of Metal Heating
Heating behaviour of metal plate with a
susceptor in a microwave oven was simulated
with Comsol Multiphysics software version
4.0a. The simulation was done for an
aluminium plate of 3 mm thickness covered by
a microwave transparent material to prevent
reflection. As the action of spring loaded drill
is mechanical it was not included to study the
heating behaviour of specimen. Charcoal
susceptor was place at a hole in the centre of
the specimen and the heating simulation was
done at a power of 900 W for a time of 300 s
and 180 s. The heating profile after 300 s is
given in Figure3 and the temperature change
with respect to time at a point on the top of the
metal plate is given in Figure 4.
Table 1: Parameters Used in the Microwave Drilling Trials.

Material
Output
Time of
Drill Feature
power of
exposure
(diameter
microwave
(s)
mm)
Aluminium 1
900 W
120
Tungsten (2)
Copper
900 W
150
Tungsten (2)
Mild steel
900 W
240
Tungsten (2)
Aluminium 2
900 W
60
SS (0.8)
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George et al.
__________________________________________________________________________________________
Fig. 3: Temperature Profile of the Metal Plate during Microwave Heating.
Fig. 4: Graph Showing the Change in Temperature with Time of the Metal Plate in Simulation.
RESULTS AND ANALYSIS
The first Al specimen drilled with 2 mm tool
was melted and burned partially due to
overheating. Temperature indicated in the
device connected to thermocouple was about
640 0C at the edge of the specimen. But a hole
was formed and is shown in Figure 5 (a). The
heating time was 120 s but the charcoal started

complete coupling in 30 s. The Al specimen
shows overheating on the area near to hole.
This is due to low melting temperature of Al
(about 659 0C) and non uniformity in placing
the charcoal at the target area.
Page 13

Fig. 5: (a) Al Specimen Partially Burnt, with a

2 mm Diameter Hole (b) Partially Drilled
Stainless Steel Specimen.
Fig. 7: SEM Image of a 0.8mm Diameter Hole

Drilled in Aluminium of 1 mm.
Fig. 6: (a) Al Specimen with 0.8 mm Hole (b)
Copper Strip with 2 mm Diameter Hole.
The mild steel specimen was pierced partially
with 2 mm diameter tool. Even after 240 s of
exposure to microwave, though it got red hot,
yet the temperature rise was not sufficient to
form a hole. The temperature measured on the
specimen just after 240 s of heating was about
850 0C. It was partially drilled; the photograph
of the partially drilled specimen is given in
Figure 5(b). Second Aluminium specimen was
drilled with a stainless steel rod of 0.8mm
diameter with heating 60 s which is shown in
Figure 6(a) and the SEM image of that hole is
given in Figure 7. The profile of the hole has
good finish and shape. The photograph of the
drilled copper strip is given in Figure 6(b). The
temperature measured at the time of drilling
was about 720 0C.
To study the surface microstructure, SEM

micrographs of the specimens were taken
before and after drilling. No variation was
observed in the surface structure of
Aluminium and the SEM image of surface
before and after microwave drilling is given in
Figure 8. Very small variation in grain size
(grain coarsening) of copper as per Figure 9
was observed where as the increase in grain
size comparatively more in case of mild steel
was given in Figure 10. This may be due to
overall heating of the specimen with charcoal
and the time of heating was more in case of
copper and mild steel. This can be minimised
by proper concentration of microwave to the
drilling point and reducing the amount of
susceptor to be used.
Fig. 8: SEM Micrograph of the Aluminium Specimen (a) After Microwave Drilling
(b) Before Drilling.
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George et al.
__________________________________________________________________________________________
Fig. 9: SEM Micrograph of the Copper Specimen (a) Before Microwave Drilling (b) After Drilling.
Fig. 10: SEM Micrograph of MS Specimen (a) After Microwave Drilling (b) Before Microwave
Drilling.
Temperature profile given by simulation is
showing the localised heating of specimen by
microwaves. The maximum temperature on
the 2 mm Al plate is on the top surface and
about 3800C. Contemporary studies suggest
that if the temperature is about 70% of the
melting point, the shear stress will be reduced
more than 75% and the metal will lose its
strength so that the drill penetrates easily [14,
15]. In this simulation the temperature is less
than the experimental setup because the fixture
hinders the microwave, but in the experiments
performed, the fixture was placed on a rotary
table for uniform distribution of microwave.
DRILLING OF GLASS
Experimental Procedure
The procedure was almost same as that
followed for metals. Specimen was not
covered as glass will not reflect microwaves.
Also susceptor was not needed as a metallic
drill touches the glass in presence of
microwave a spark initiates and it continues to
become a plasma formation. Here the tungsten
rod itself will acts as a receiving and
transmitting antenna for microwaves so that all
charge will concentrate at the tip of the drill

bit. The heat developed due to plasma is
sufficient to drill the glass without any
preloaded force from the spring. Here the
temperature measuring was not effective as the
specimen was non conductor of heat and the
plasma was formed at the point of contact
between specimen and metallic rod only. Self
weight of the drill is sufficient to deform the
glass.
The experiments were done with microwaves
of frequency 2.45 GHz at 600 W power in a
multimode applicator. The experiments were
performed on borosilicate glass of 1.5 mm and
4 mm thickness and the hole was drilled in 4 s
and 8 s respectively. When the power or time
of exposure is more the glass breaks due to
thermal shock or high temperature. The
photograph of plasma formed in glass drilling
is given in Figure 11.
Simulation of Microwave Heating in Glass
Drilling
Temperature profile for the drilling of glass
with a metal rod in a microwave oven was
simulated using Comsol Multiphysics
Page 15

software. Simulation was done at 700 W

power for a time of 30 s on silica glass of 10
mm thickness The drill bit was cylindrical rod
of stainless steel having 3mm diameter. Only
the glass specimen and drill bit was included
in simulation as other parts are for holding the
specimen and drill bit and doesnt have any
role in the heating and plasma formation. The
temperature profile over glass and the graph of
temperature at the contact between glass and
drill plotted by simulation software was given
in Figures 12 and 13.
Fig. 11: Plasma Formation in Drilling Glass.
Fig. 12: Heating Profile During Glass Drilling.
Fig. 13: Temperature at the Point of Contact Between Drill Bit and Glass.
Page 16

George et al.
__________________________________________________________________________________________
Fig. 14: (a) Photograph of the Drilled Glass Specimen (b) SEM Image of the Drilled Hole in
Borosilicate Glass.
Results and Discussion
Photograph of a drilled glass specimen is
given in Figure 11. Most of the specimens
were broken suddenly after switching on the
power. The surface finish was not good and
some cracks were visible around the hole.
These problems can be reduced by optimising
the parameters like power, time and by
selecting a drill bit of suitable metal. As glass
is very brittle the application of force on the
glass must be minimised to prevent the
breakage.
Simulations results are showing an increase in
temperature of 150 C which is much lower
than the actual value. This may be the
limitation of software to calculate the
temperature of plasma which is not
continuous. Also the software will calculate
the temperature around the specimen and drill
bit only and not the nearby surroundings
where plasma is formed like a sphere. By
concentrating the microwave by transmitting
from a single point the size of plasma can be
controlled which will reduce the heat affected
zone and can be applied to various non metals.
CONCLUSIONS
The process of microwave drilling was proved
for metals by microwave hybrid heating. The
same technique can be applied to non metals
also with the formation of plasma. The
formation of plasma in drilling of glass shows

the possibility of developing plasma cutting
and heating technique with microwave.
Optimisation of the parameters needs to be
studied more.
Microwave drilling can be developed to an
integrated tooling for various industrial
applications by making a setup which is
mobile and concentrating microwave to a point
similar to the schematic diagram given in
Figure 16 in which the microwave energy is
properly tuned and coming out through a
unidirectional antenna. These waves will be
concentrated to a single point which can be
heated and drilled by the same process
described in this paper. But the leakage of
microwaves can be dangerous and its illeffects on human body restrict its use in open
environment. Holes of any shape can be made
by using the drill of same shape. Proper tuning
of the waves for impedance matching will help
to concentrate it to a small area and thereby
reducing the heat affected zone. This can
prevent the changes in grain structure. The
plastic deformation observed in drilling of
metals shows the possibility of a new
technology Microwave Assisted Metal
Forming. A setup which can be used in a
production line where continuous flow of
materials along with microwave heating for
metal forming is given in Figure 15.
Page 17

Fig. 15: Schematic Diagram of a Proposed Microwave Assisted Metal Forming System.
Fig. 16: Proposed Setup to Develop

Microwave Drilling.
ACKNOWLEDGEMENT
The financial assistance received for carrying
out the works presented in the paper vide
BRNS Research Project No.DAE-546-MID is
thankfully acknowledged. Authors gratefully
acknowledge the inputs received from research
students Dheeraj Gupta, Amit Bansal and
Vivek Jain.
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