The edge rounding of brittle materials by vibratory finishing, VF, was investigated. Borosilicate glass and silicon nitride specimens were processed in two typical VF setups. In all cases, the processed specimens exhibited wear and chipping at their edges, whereas their flat surfaces remained intact. Edge chipping was strongly affected by the edge geometry and process parameters such as the media size and vibration amplitude of the finisher. Therefore, to achieve smooth chip-less edge, samples were processed in several steps, starting with the least energetic conditions, followed by more energetic ones as the edge became progressively blunter. The analysis of edge wear by VF revealed a new mechanism of wear, not previously reported in the literature. A stochastic numerical model was subsequently developed to model this mechanism of wear. To confirm the validity of the model, the model predictions were compared to the experimental observations of wear in the vibratory finisher. The model was used to investigate the effect of various VF process parameters on the edge wear of brittle materials. A VF simulator was used to investigate wear and chipping under more controlled conditions. The VF simulator launched particles against the specimens at adjustable velocities and impact angles. The effect of particles’ shape, and impact velocity and angle, on the wear of glass edges was investigated. Fundamental differences were observed between wear by abrasive and smooth particles. These differences were attributed to the mechanisms of material removal by abrasive iii and smooth balls. Abrasive balls remove material by the sharp indentation of their surface asperities, whereas smooth particles lack such sharp peaks and hence apply blunt indentation on the edges. To identify the fundamental differences between material removal by sharp and blunt indenters, a series of indentation experiments were carried out on glass edges. Subsequently, these differences were discussed in terms of their implications on wear by abrasive and smooth particles.

The edge rounding of brittle materials by vibratory finishing, VF, was investigated. Borosilicate glass and silicon nitride specimens were processed in two typical VF setups. In all cases, the processed specimens exhibited wear and chipping at their edges, whereas their flat surfaces remained intact. Edge chipping was strongly affected by the edge geometry and process parameters such as the media size and vibration amplitude of the finisher. Therefore, to achieve smooth chip-less edge, samples were processed in several steps, starting with the least energetic conditions, followed by more energetic ones as the edge became progressively blunter. The analysis of edge wear by VF revealed a new mechanism of wear, not previously reported in the literature. A stochastic numerical model was subsequently developed to model this mechanism of wear. To confirm the validity of the model, the model predictions were compared to the experimental observations of wear in the vibratory finisher. The model was used to investigate the effect of various VF process parameters on the edge wear of brittle materials. A VF simulator was used to investigate wear and chipping under more controlled conditions. The VF simulator launched particles against the specimens at adjustable velocities and impact angles. The effect of particles’ shape, and impact velocity and angle, on the wear of glass edges was investigated. Fundamental differences were observed between wear by abrasive and smooth particles. These differences were attributed to the mechanisms of material removal by abrasive iii and smooth balls. Abrasive balls remove material by the sharp indentation of their surface asperities, whereas smooth particles lack such sharp peaks and hence apply blunt indentation on the edges. To identify the fundamental differences between material removal by sharp and blunt indenters, a series of indentation experiments were carried out on glass edges. Subsequently, these differences were discussed in terms of their implications on wear by abrasive and smooth particles.

PURPOSE: To analyze surface roughness, the edge chipping of different CAD/CAM bur milled dental materials (bar and crown design of 1.0mm and 1.5mm thickness), correlate the effect of machining damage on the material strength, compare the flexural strength of bur milled versus sectioned CAD/CAM blocks and evaluate the tool wear after milling. MATERIALS AND METHODS: Five dental CAD/CAM materials were used: Lithium disilicate glass-ceramic (IPS e.max CAD), Leucite-reinforced glass-ceramic (IPS Empress CAD), Feldspathic porcelain (Vitablocs Mark II), Feldspar ceramic-polymer infiltrated (Enamic), and composite resin (Lava Ultimate). Ten rectangular bars with dimensions of 4 mm × 2 mm × 14 mm were milled using a new set of burs for each material. Then, ten crowns of each material with thicknesses of 1.0 mm and 1.5 mm were milled after scanning a standard aluminum die with corresponding marginal thickness. The bars surface roughness was measured. Then, three specimens were selected for the edge chipping analysis using (SEM). Thereafter, 3-point bend test was used to test the flexural strength of bur milled and saw cut bars with the same dimensions. For the crowns, load to failure test was used. One-way ANOVA and Tukey HSD post hoc tests to determine the difference between the groups using JMP13.0 with α=0.05. RESULTS AND CONCLUSIONS: The surface roughness and edge chipping was significantly affected by the material composition. Comparison of the flexural strength of bur milled to sectioned bars, IPS e.max CAD and IPS Empress CAD show statistically significant less flexural strength (p<0.001). A strong correlation was found between the decrease in flexural strength and the chipping length on the central tensile side of the bur milled materials (R2=0.62, p=0.01). Crown thickness significantly affects the edge chipping as 1.5 mm crown thickness has more edge chipping than 1.0 mm crowns. However, no correlation is found between the load to failure test for the crown design and the edge chipping for 1.5mm and 1.0 mm thickness crowns. Tool wear is significantly affected by the material type. / 2021-07-31

Doctor of Philosophy / Department of Industrial & Manufacturing Systems Engineering / Zhijian Pei / Poor machinability of hard-to-machine materials (such as advanced ceramics and titanium) limits their applications in industries. Ultrasonic-vibration-assisted grinding (UVAG), a hybrid machining process combining material-removal mechanisms of diamond grinding and ultrasonic machining, is one cost-effective machining method for these materials. Compared to ultrasonic machining, UVAG has much higher material removal rate while maintaining lower cutting pressure and torque, reduced edge chipping and surface damage, improved accuracy, and lower tool wear rate. However, physics-based models to predict cutting force in UVAG have not been reported to date. Furthermore, edge chipping is one of the technical challenges in UVAG of brittle materials. There is no report related to effects of cutting tool design on edge chipping in UVAG of brittle materials. The goal of this research is to provide new knowledge of machining these hard-to-machine materials with UVAG for further improvements in machining cost and surface quality. First, a thorough literature review is given to show what has been done in this field. Then, a physics-based predictive cutting force model and a mechanistic cutting force model are developed for UVAG of ductile and brittle materials, respectively. Effects of input variables (diamond grain number, diamond grain diameter, vibration amplitude, vibration frequency, spindle speed, and federate) on cutting force are studied based on the developed models. Interaction effects of input variables on cutting force are also studied. In addition, an FEA model is developed to study effects of cutting tool design and input variables on edge chipping. Furthermore, some trends predicted from the developed models are verified through experiments. The results in this dissertation could provide guidance for choosing reasonable process variables and designing diamond tools for UVAG.

Objetivos: avaliar espécimes com as seguintes combinações de materiais/processamentos: a) porcelana feldspática aplicada por meio de técnica tradicional sobre infraestrutura de zircônia; b) porcelana feldspática injetada sobre infraestrutura de zircônia, c) porcelana feldspática usinada em sistema CAD-CAM e cimentada (Rapid Layer Technique) sobre infraestrutura de zircônia; d) vitro-cerâmica à base de dissilicato de lítio processada por meio de sistema CAD-CAM e unida à infraestrutura de zircônia por meio da sinterização de um vidro na interface (técnica CAD-on) com relação a: (1) resistência ao lascamento de aresta do material de recobrimento (a influência do tipo de resfriamento foi analisada para os processamentos a e b) e; (2) níveis de tensão residual superficial mensurados nos materiais de recobrimento, por meio de ensaio de fratura por endentação (a influência do tipo de resfriamento foi analisada para os processamentos a e b). Material e métodos: Barras de duas camadas com dimensões de 25 mm de comprimento por 4 mm de largura e com espessuras de porcelana e infraestrutura combinadas de modo a oferecer a razão de 1 mm de cada material foram confeccionadas seguindo as orientações dos fabricantes. O teste de lascamento de aresta foi realizado em uma máquina universal de ensaios, utilizando um endentador Vickers acoplado a essa máquina. A tensão térmica residual superficial foi calculada a partir de endentações feitas na camada de porcelana. Resultados: A resistência ao lascamento (ReA) foi significativamente maior para os espécimes processados pelo sistema CAD-on (ReA = 612,8±271,8 N/mm). Bilayers confeccionadas pelo sistema Rapid Layer Technique apresentaram valor de ReA intermediário de (417,9±187,2 N/mm) e os grupos nos quais foi utilizada porcelana processada pela técnica de sinterização tradicional ou por injeção foram os que apresentaram os menores valores de resistência ao lascamento, com médias de 349,7±116,8 N/mm (tradicional/resfriamento lento) 285,6±117,5 N/mm (tradicional/resfriamento rápido), 298,4±119,9 N/mm (injetado/resfriamento lento) e 263,5±107,9 N/mm (injetado/resfriamento rápido). Para os grupos com porcelana aplicada sobre a infraestrutura pela técnica tradicional e injetada o teste t de Student mostrou que houve um efeito significativo do protocolo de resfriamento, sendo que os espécimes que passaram por resfriamento lento atingiram maiores valores de ReA. Apenas o grupo Rapid Layer Technique apresentou média de tensão superficial correspondente a tensões de tração. Todos os outros grupos apresentaram tensões de compressão na superfície. Conclusões: há um efeito significativo da associação material/processamento na resistência ao lascamento de aresta das bilayers testadas e com relação ao efeito da velocidade de resfriamento (lento e rápido). Os espécimes que passaram por resfriamento lento atingiram maiores valores de resistência ao lascamento, independentemente do método de processamento (tradicional ou injeção). A combinação material/processamento afetou significativamente as tensões residuais superficiais das bilayers testadas, porém, não houve efeito da velocidade de resfriamento no nível de tensões térmicas residuais superficiais para os espécimes processados tanto pela técnica tradicional como pela técnica de injeção. / Objectives: to evaluate specimens with the following materials/processing combinations: a) feldspathic porcelain applied on zirconia through traditional technique; b) feldspathic porcelain applied on zirconia through press-on technique, c) feldspathic porcelain milled in CAD-CAM system and cemented (Rapid Layer Technique) on zirconia infrastructure; D) lithium disilicate glass-ceramic milled in CAD-CAM system and bonded to the zirconia infrastructure by means of a fusion glass-ceramic applied at the interface (CAD-on technique) relating to: (1) edge chipping resistance of the veneering materials (influence of the cooling rate was analyzed for the processing methods a and b) and; (2) surface residual stress levels measured in the veneering materials through indentation fracture method (influence of the cooling rate was analyzed for the processing methods a and b). Materials and methods: Bilayer bars with 25 mm length, 4 mm width and thicknesses of porcelain and infrastructure combined to provide 1 mm ratio of each material were made following manufacturers\' instructions. The edge chipping test was performed in an universal testing machine, using a Vickers indenter coupled to it. The surface residual thermal stress was calculated from indentations made on the porcelain layer. Results: The chipping resistance (ReA) was significantly higher for the specimens processed by the CAD-on system (ReA = 612.8±271.8 N/mm). Bilayers made by the Rapid Layer Technique system presented an intermediate ReA mean value of 417.9±187.2 N/mm and the groups in which the porcelain layer was processed by traditional or press-on technique presented the lowest values of chipping resistance, with mean values of 349,7±116,8 N/mm (traditional/slow cooling) 285,6±117,5 N/mm (traditional/fast cooling), 298,4±119,9 N/mm (press-on/slow cooling) and 263,5±107,9 N/mm (press-on/fast cooling). For the groups with porcelain applied on the infrastructure by the traditional and press-on technique, Student\'s t test showed that there was a significant effect of the cooling rate, and the specimens that went through slow cooling rate reached higher ReA values. Only the Rapid Layer Technique group presented mean of surface stresses corresponding to tensile stresses. All other groups exhibited surface compression stresses. Conclusions: there is a significant effect of the material/processing association on the edge chipping resistance of the tested bilayers and regarding the cooling rate effect (slow and fast), the specimens that went through slow cooling rate reached higher values of edge chipping resistance, regardless of the processing method (traditional or press-on). The material/processing combination significantly affected the surface residual stresses of the tested bilayers, however, there was no effect of the cooling rate on the superficial residual thermal stresses levels for the specimens processed by both the traditional technique and the press-on technique.

Objetivos: avaliar espécimes com as seguintes combinações de materiais/processamentos: a) porcelana feldspática aplicada por meio de técnica tradicional sobre infraestrutura de zircônia; b) porcelana feldspática injetada sobre infraestrutura de zircônia, c) porcelana feldspática usinada em sistema CAD-CAM e cimentada (Rapid Layer Technique) sobre infraestrutura de zircônia; d) vitro-cerâmica à base de dissilicato de lítio processada por meio de sistema CAD-CAM e unida à infraestrutura de zircônia por meio da sinterização de um vidro na interface (técnica CAD-on) com relação a: (1) resistência ao lascamento de aresta do material de recobrimento (a influência do tipo de resfriamento foi analisada para os processamentos a e b) e; (2) níveis de tensão residual superficial mensurados nos materiais de recobrimento, por meio de ensaio de fratura por endentação (a influência do tipo de resfriamento foi analisada para os processamentos a e b). Material e métodos: Barras de duas camadas com dimensões de 25 mm de comprimento por 4 mm de largura e com espessuras de porcelana e infraestrutura combinadas de modo a oferecer a razão de 1 mm de cada material foram confeccionadas seguindo as orientações dos fabricantes. O teste de lascamento de aresta foi realizado em uma máquina universal de ensaios, utilizando um endentador Vickers acoplado a essa máquina. A tensão térmica residual superficial foi calculada a partir de endentações feitas na camada de porcelana. Resultados: A resistência ao lascamento (ReA) foi significativamente maior para os espécimes processados pelo sistema CAD-on (ReA = 612,8±271,8 N/mm). Bilayers confeccionadas pelo sistema Rapid Layer Technique apresentaram valor de ReA intermediário de (417,9±187,2 N/mm) e os grupos nos quais foi utilizada porcelana processada pela técnica de sinterização tradicional ou por injeção foram os que apresentaram os menores valores de resistência ao lascamento, com médias de 349,7±116,8 N/mm (tradicional/resfriamento lento) 285,6±117,5 N/mm (tradicional/resfriamento rápido), 298,4±119,9 N/mm (injetado/resfriamento lento) e 263,5±107,9 N/mm (injetado/resfriamento rápido). Para os grupos com porcelana aplicada sobre a infraestrutura pela técnica tradicional e injetada o teste t de Student mostrou que houve um efeito significativo do protocolo de resfriamento, sendo que os espécimes que passaram por resfriamento lento atingiram maiores valores de ReA. Apenas o grupo Rapid Layer Technique apresentou média de tensão superficial correspondente a tensões de tração. Todos os outros grupos apresentaram tensões de compressão na superfície. Conclusões: há um efeito significativo da associação material/processamento na resistência ao lascamento de aresta das bilayers testadas e com relação ao efeito da velocidade de resfriamento (lento e rápido). Os espécimes que passaram por resfriamento lento atingiram maiores valores de resistência ao lascamento, independentemente do método de processamento (tradicional ou injeção). A combinação material/processamento afetou significativamente as tensões residuais superficiais das bilayers testadas, porém, não houve efeito da velocidade de resfriamento no nível de tensões térmicas residuais superficiais para os espécimes processados tanto pela técnica tradicional como pela técnica de injeção. / Objectives: to evaluate specimens with the following materials/processing combinations: a) feldspathic porcelain applied on zirconia through traditional technique; b) feldspathic porcelain applied on zirconia through press-on technique, c) feldspathic porcelain milled in CAD-CAM system and cemented (Rapid Layer Technique) on zirconia infrastructure; D) lithium disilicate glass-ceramic milled in CAD-CAM system and bonded to the zirconia infrastructure by means of a fusion glass-ceramic applied at the interface (CAD-on technique) relating to: (1) edge chipping resistance of the veneering materials (influence of the cooling rate was analyzed for the processing methods a and b) and; (2) surface residual stress levels measured in the veneering materials through indentation fracture method (influence of the cooling rate was analyzed for the processing methods a and b). Materials and methods: Bilayer bars with 25 mm length, 4 mm width and thicknesses of porcelain and infrastructure combined to provide 1 mm ratio of each material were made following manufacturers\' instructions. The edge chipping test was performed in an universal testing machine, using a Vickers indenter coupled to it. The surface residual thermal stress was calculated from indentations made on the porcelain layer. Results: The chipping resistance (ReA) was significantly higher for the specimens processed by the CAD-on system (ReA = 612.8±271.8 N/mm). Bilayers made by the Rapid Layer Technique system presented an intermediate ReA mean value of 417.9±187.2 N/mm and the groups in which the porcelain layer was processed by traditional or press-on technique presented the lowest values of chipping resistance, with mean values of 349,7±116,8 N/mm (traditional/slow cooling) 285,6±117,5 N/mm (traditional/fast cooling), 298,4±119,9 N/mm (press-on/slow cooling) and 263,5±107,9 N/mm (press-on/fast cooling). For the groups with porcelain applied on the infrastructure by the traditional and press-on technique, Student\'s t test showed that there was a significant effect of the cooling rate, and the specimens that went through slow cooling rate reached higher ReA values. Only the Rapid Layer Technique group presented mean of surface stresses corresponding to tensile stresses. All other groups exhibited surface compression stresses. Conclusions: there is a significant effect of the material/processing association on the edge chipping resistance of the tested bilayers and regarding the cooling rate effect (slow and fast), the specimens that went through slow cooling rate reached higher values of edge chipping resistance, regardless of the processing method (traditional or press-on). The material/processing combination significantly affected the surface residual stresses of the tested bilayers, however, there was no effect of the cooling rate on the superficial residual thermal stresses levels for the specimens processed by both the traditional technique and the press-on technique.

Doctor of Philosophy / Department of Industrial & Manufacturing Systems Engineering / Shuting Lei / This study experimentally and numerically investigates laser assisted milling (LAMill) of silicon nitride ceramics. Experiments are conducted to study the machinability of Si3N4 under LAMill. The effects of temperature on cutting forces, tool wear, surface integrity, edge chipping and material removal mechanisms are investigated. It is shown that when temperature increases, cutting force and tool wear are significantly decreased, surface integrity is improved, chip size is increased and material removal demonstrates more plastic characteristics. The mechanisms of edge chipping at elevated temperature are investigated theoretically and experimentally. When temperature is above the softening point and below the brittle/ductile transition temperature, the mechanism is mainly through softening. When temperature is above the brittle/ductile transition temperature, toughening mechanism contributes significantly to the reduced edge chipping. The coupled effect of softening and toughening mechanisms shows that temperature range between 1200 to 1400°C has the most significant effect to reduce edge chipping. Distinct element method (DEM) is applied to simulate the micro-mechanical behavior of Si3N4. First, quantitative relationships between particle level parameters and macro-properties of the bonded particle specimens are obtained, which builds a foundation for simulation of Si3N4. Then, extensive DEM simulations are conducted to model the material removal of machining Si3N4. The simulation results demonstrate that DEM can reproduce the conceptual material removal model summarized from experimental observations, including the initiation and propagation of cracks, chip formation process and material removal mechanisms. It is shown that material removal is mainly realized by propagation of lateral cracks in machining of silicon nitride. At the elevated temperature under laser assisted machining, lateral cracks are easier to propagate to form larger machined chips, there are fewer and smaller median cracks therefore less surface/subsurface damage, and crushing-type material removal is reduced. The material removal at elevated temperature demonstrates more plastic characteristics. The numerical results agree very well with experimental observations. It shows that DEM is a promising method to model the micro-mechanical process of machining Si3N4.

Objetivos: aprofundar na interpretação dos dados obtidos pelo teste de lascamento da aresta, com espécime em formato de barra ou de coroa, para verificar se o ensaio é capaz de reproduzir o resultado já conhecido na clínica de que porcelana sobre zircônia apresenta maior facilidade de lascamento do que porcelana sobre metal, quando o resfriamento rápido é adotado. Material e método: o teste de lascamento da aresta foi aplicado em espécimes com dois formatos: barras (monolíticas: de VM13, VM9 ou zircônia; ou em duas camadas: de VM13-metal ou VM9-zircônia) e coroas (sempre com duas camadas). Nas barras monolíticas (5 mm x 32 mm x 2,5 mm) foi realizada uma análise da microestrutura para avaliar eventuais diferenças entre a VM13 e a VM9, que poderiam interferir na interpretação de diferenças encontradas nos espécimes de duas camadas. As barras com duas camadas (5 mm x 32 mm x 2,2 mm, com infraestrutura de 0,7 mm e porcelana de 1,5) receberam dois protocolos de resfriamento (lento e rápido) e foram testadas em duas direções de carregamento (paralela ou perpendicular à interface). Para estes espécimes foram avaliadas as tensões térmicas residuais por análise por elementos finitos. Para as coroas (correspondentes ao primeiro molar inferior, com infraestrutura de 0,7 mm de espessura), foram utilizados os mesmos protocolos de resfriamento das barras de duas camadas. As superfícies de fraturas de todos os espécimes foram analisadas em estereomicroscópio com um aumento de 20x a 50x. Os dados de lascamento foram analisados através de diferentes abordagens apresentadas na literatura, sendo o parâmetro ReA (resistência ao lascamento), correspondente à média de todas as razões de força necessária para criar a lasca pela distância da aresta (N/mm), o escolhido para comparar os vários grupos experimentais. Resultados: não foram encontradas diferenças estatisticamente significantes entre as resistências ao lascamento das porcelanas, apesar da VM13 apresentar maior fração de área de leucita. Nas barras de duas camadas resfriadas lentamente e carregadas na direção perpendicular à interface, a zircônia proporcionou resistência ao lascamento da porcelana estatisticamente superior à proporcionada pelo metal. Quando o resfriamento rápido foi utilizado ou quando o carregamento foi paralelo à interface, o teste não foi capaz de evidenciar diferenças entre os grupos. Nas coroas submetidas ao resfriamento rápido, o metal proporcionou resistência ao lascamento da porcelana estatisticamente superior à proporcionada pela zircônia. Quando o resfriamento lento foi utilizado, o teste não foi capaz de evidenciar diferenças entre grupos com materiais de infraestrutura distintos. Conclusão: O ensaio de lascamento em coroas reproduziu melhor que o ensaio de lascamento em barras a resistência ao lascamento relatada na clínica. Assim, esforços em aprimorar o teste utilizando espécimes com geometria mais semelhante à da coroa são importantes. / Aim: To deepen the investigation of the edge chipping method when using either bar or crown-shaped specimens, to verify whether the test is able to reproduce the well-known clinical outcome that veneered zirconia is more prone to chipping than porcelain-fused-to-metal when the fast cooling protocol is used. Materials and methods: edge chipping test was conducted with different shaped specimens: bars (monolithic: VM13, VM9 or zirconia; or bilayers: VM13-metal and VM9-zirconia) and bi-layer crowns. A microstructure analysis was performed on the monolithic bars (5 mm x 32 mm x 2.5 mm) to evaluate possible differences between VM13 and VM9, that could account for differences on bilayer specimens data. The bilayer bars (5 mm x 32 mm x 2.2 mm, 0.7 mm and 1.5 porcelain infrastructure) were subjected to two cooling protocols (slow and fast) and load was applied in two directions (parallel or perpendicular to the interface). For bilayer bars, residual thermal stresses were evaluated using finite element analysis. For crown-shaped specimens (corresponding to the first molar, with 0.7 mm framework thickness), the cooling protocol was the same employed for bilayer bars. The fractured surfaces of all specimens were examined utilizing a stereomicroscope at a magnification from 20x up to 50x. The edge chipping data were analyzed by several approaches presented in the literature, the ReA parameter (chipping resistance), corresponding to the average of force versus distance data collected over a broad range (N / mm), was chosen to compare the different experimental groups. Results: There was no significant difference between the veneers for chipping resistance, despite that VM13 presented the highest leucite content. On bilayer bars with slow cooling protocol and loading perpendicular to the interface, zirconia provided significantly higher chipping resistance than metal-based specimens. Edge chipping test was not able to detect differences between groups when fast cooling was used or loading was applied parallel to the interface. When crowns were subject to fast cooling, results revealed that metal framework has significantly higher veneer chipping resistance than zirconia. When the slow cooling protocol was used, differences between groups with different frameworks were not observed using edge chipping test. Conclusion: The chipping test on crowns reproduced the chipping resistance reported clinically better than bar-shaped specimens. Thus, efforts to improve the test using specimens more similar to the crown geometry are important.

Objetivos: aprofundar na interpretação dos dados obtidos pelo teste de lascamento da aresta, com espécime em formato de barra ou de coroa, para verificar se o ensaio é capaz de reproduzir o resultado já conhecido na clínica de que porcelana sobre zircônia apresenta maior facilidade de lascamento do que porcelana sobre metal, quando o resfriamento rápido é adotado. Material e método: o teste de lascamento da aresta foi aplicado em espécimes com dois formatos: barras (monolíticas: de VM13, VM9 ou zircônia; ou em duas camadas: de VM13-metal ou VM9-zircônia) e coroas (sempre com duas camadas). Nas barras monolíticas (5 mm x 32 mm x 2,5 mm) foi realizada uma análise da microestrutura para avaliar eventuais diferenças entre a VM13 e a VM9, que poderiam interferir na interpretação de diferenças encontradas nos espécimes de duas camadas. As barras com duas camadas (5 mm x 32 mm x 2,2 mm, com infraestrutura de 0,7 mm e porcelana de 1,5) receberam dois protocolos de resfriamento (lento e rápido) e foram testadas em duas direções de carregamento (paralela ou perpendicular à interface). Para estes espécimes foram avaliadas as tensões térmicas residuais por análise por elementos finitos. Para as coroas (correspondentes ao primeiro molar inferior, com infraestrutura de 0,7 mm de espessura), foram utilizados os mesmos protocolos de resfriamento das barras de duas camadas. As superfícies de fraturas de todos os espécimes foram analisadas em estereomicroscópio com um aumento de 20x a 50x. Os dados de lascamento foram analisados através de diferentes abordagens apresentadas na literatura, sendo o parâmetro ReA (resistência ao lascamento), correspondente à média de todas as razões de força necessária para criar a lasca pela distância da aresta (N/mm), o escolhido para comparar os vários grupos experimentais. Resultados: não foram encontradas diferenças estatisticamente significantes entre as resistências ao lascamento das porcelanas, apesar da VM13 apresentar maior fração de área de leucita. Nas barras de duas camadas resfriadas lentamente e carregadas na direção perpendicular à interface, a zircônia proporcionou resistência ao lascamento da porcelana estatisticamente superior à proporcionada pelo metal. Quando o resfriamento rápido foi utilizado ou quando o carregamento foi paralelo à interface, o teste não foi capaz de evidenciar diferenças entre os grupos. Nas coroas submetidas ao resfriamento rápido, o metal proporcionou resistência ao lascamento da porcelana estatisticamente superior à proporcionada pela zircônia. Quando o resfriamento lento foi utilizado, o teste não foi capaz de evidenciar diferenças entre grupos com materiais de infraestrutura distintos. Conclusão: O ensaio de lascamento em coroas reproduziu melhor que o ensaio de lascamento em barras a resistência ao lascamento relatada na clínica. Assim, esforços em aprimorar o teste utilizando espécimes com geometria mais semelhante à da coroa são importantes. / Aim: To deepen the investigation of the edge chipping method when using either bar or crown-shaped specimens, to verify whether the test is able to reproduce the well-known clinical outcome that veneered zirconia is more prone to chipping than porcelain-fused-to-metal when the fast cooling protocol is used. Materials and methods: edge chipping test was conducted with different shaped specimens: bars (monolithic: VM13, VM9 or zirconia; or bilayers: VM13-metal and VM9-zirconia) and bi-layer crowns. A microstructure analysis was performed on the monolithic bars (5 mm x 32 mm x 2.5 mm) to evaluate possible differences between VM13 and VM9, that could account for differences on bilayer specimens data. The bilayer bars (5 mm x 32 mm x 2.2 mm, 0.7 mm and 1.5 porcelain infrastructure) were subjected to two cooling protocols (slow and fast) and load was applied in two directions (parallel or perpendicular to the interface). For bilayer bars, residual thermal stresses were evaluated using finite element analysis. For crown-shaped specimens (corresponding to the first molar, with 0.7 mm framework thickness), the cooling protocol was the same employed for bilayer bars. The fractured surfaces of all specimens were examined utilizing a stereomicroscope at a magnification from 20x up to 50x. The edge chipping data were analyzed by several approaches presented in the literature, the ReA parameter (chipping resistance), corresponding to the average of force versus distance data collected over a broad range (N / mm), was chosen to compare the different experimental groups. Results: There was no significant difference between the veneers for chipping resistance, despite that VM13 presented the highest leucite content. On bilayer bars with slow cooling protocol and loading perpendicular to the interface, zirconia provided significantly higher chipping resistance than metal-based specimens. Edge chipping test was not able to detect differences between groups when fast cooling was used or loading was applied parallel to the interface. When crowns were subject to fast cooling, results revealed that metal framework has significantly higher veneer chipping resistance than zirconia. When the slow cooling protocol was used, differences between groups with different frameworks were not observed using edge chipping test. Conclusion: The chipping test on crowns reproduced the chipping resistance reported clinically better than bar-shaped specimens. Thus, efforts to improve the test using specimens more similar to the crown geometry are important.