Burr Formation and Surface Characteristics in Micro-End Milling of Titanium Alloys

2009 ◽  
pp. 129-138 ◽  
Author(s):  
G.M. Schueler ◽  
J. Engmann ◽  
T. Marx ◽  
R. Haberland ◽  
J.C. Aurich
Keyword(s):  
Titanium Alloys ◽  
End Milling ◽  
Surface Characteristics ◽  
Burr Formation ◽  
Micro End Milling

Prediction of Burr Formation in Fabricating MEMS Components by Micro End Milling

2009 ◽  
Vol 74 ◽  
pp. 247-250 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Mohd Aliff Omar ◽  
Khairul Irman Othman ◽  
Wayne N.P. Hung
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Burr Formation ◽  
Aisi 304 ◽  
Burr Height ◽  
Milling Parameters ◽  
Milling Tool ◽  
Micro End Milling ◽  
Chip Load

This paper discusses burr formation in micromilling of AISI 304 stainless steel. Chip load, cutting speed and the application of coolant were chosen as the milling parameters. Experiments were conducted using 500 µm diameter tungsten carbide end milling tool. Milling parameters and measured burr height values were analyzed and statistical models were developed for the estimation of burr height. The models showed that the chip load and cutting speed both have direct and interactive contribution to burr formation. When micromachining without coolant, the burr height increases about 40% compared to that of machining with coolant. The optimized values of chip load and cutting speed were found to be 1 µm/tooth and 78 mms-1 respectively. The predicted burr heights were 5-7% larger than that of measured values.

Experimental investigation of top burr formation in high-speed micro-end milling of titanium alloy

2018 ◽  
Vol 22 (6) ◽  
pp. 989-1011 ◽  
Author(s):  
Chakradhar Bandapalli ◽  
Kundan Kumar Singh ◽  
Bharatkumar Mohanbhai Sutaria ◽  
Dhananjay Vishnuprasad Bhatt
Keyword(s):  
Experimental Investigation ◽  
Titanium Alloy ◽  
High Speed ◽  
End Milling ◽  
Burr Formation ◽  
Micro End Milling

scholarly journals Evaluation of Ball End Micromilling for Ti6Al4V ELI Microneedles Using a Nanoadditive Under MQL Condition

2021 ◽  
Author(s):  
Pavel Celis ◽  
Elisa Vazquez ◽  
Cintya G. Soria-Hernández ◽  
Diego Bargnani ◽  
Ciro A. Rodriguez ◽  
...  
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Experimental Tests ◽  
Burr Formation ◽  
Tool Performance ◽  
Micro End Milling ◽  
Product Surface ◽  
Microneedle Arrays ◽  
The Impact ◽  
Minimum Quantity Of Lubrication

AbstractThe use of nanoadditives in lubricants has gained much attention to the research community due to the enhancement of tribological properties and cooling capabilities. This paper studies the advantages of using a MQL (Minimum Quantity of Lubrication) system and nanoadditive in the manufacture of microneedle arrays in Ti6Al4V ELI alloy. Tungsten carbide ball nose tools with a cutting diameter of 200 µm were used in experimental tests. Surface and dimensional characterization was performed to evaluate the impact of a nanoadditive to a vegetable-based oil. Additionally, cutting forces and cutting edge radius (CER) were measured while needles were machined. Experimental tests confirmed that micro end milling with nanoadditives provide slightly better dimensional features and low cutting forces compared to oil. The performance of nanoadditives resulted in a reduction of surface roughness (~ 0.3 μm). Qualitative study of microneedles illustrated burr formation on needle surface manufactured without a nanoadditive solution. Results reveal an increment of CER using low feed rate values (2.0 µm/flute) while a reduction of CER was observed with feed rates up to 2.5 µm/flute. Our results indicated that the addition of nanoadditives to vegetable oil promotes a better product surface topography and cutting tool performance.

Effect of Laser Preheating the Workpiece on Micro-End Milling of Metals

2005 ◽  
Author(s):  
Yongho Jeon ◽  
Frank Pfefferkorn
Keyword(s):  
Yield Strength ◽  
End Milling ◽  
Direct Method ◽  
Burr Formation ◽  
Transfer Model ◽  
Flexural Stiffness ◽  
Micro End Milling ◽  
End Mills ◽  
Tool Diameter ◽  
Chip Load

Micro-end milling is a fast and direct method of creating net-shaped functional micro parts, micro molds, and prototypes. However, the materials that can be micro machined efficiently are limited by the small flexural stiffness, strength, and hardness of the tool. The small flexural stiffness and strength of micro-end mills limits the size of cut that can be taken and the productivity. The flexural stiffness and strength are a strong function of the tool diameter. It is not expected that in the near term a new material will be developed that offers a combination of hardness and yield strength that will result in a significantly improved strength for tools with diameters measured in the 10s and 100s of microns. To enable a significant increase in performance requires higher spindle speeds and increased chip loads. Laser-assisted micro-end milling has the potential to increase the chip load and productivity by reducing the yield strength at the cutting location. This study examines the effect of laser preheating on micro-end milling of 6061-T6 aluminum and 1018 steel. 300 micron-diameter, two-flute, carbide end mills are used to cut 85 micron-deep slots at a constant 40,000 rpm spindle speed. The laser power and chip load are varied, including no preheating, to show their effect on cutting forces, specific cutting energy, burr formation, surface finish, and temperature. The results are related to average material removal temperature by predictions from a heat transfer model of the workpiece undergoing laser preheating. Results indicate that chip load and productivity can be significantly increased during dry machining of 6061-T6 aluminum and 1018 steel by locally preheating the workpiece immediately ahead of the micro-end mill.

scholarly journals Micro-end milling of NiTi biomedical alloys, burr formation and phase transformation

2014 ◽  
Vol 38 (2) ◽  
pp. 356-364 ◽  
Author(s):  
R. Piquard ◽  
A. D’Acunto ◽  
P. Laheurte ◽  
D. Dudzinski
Keyword(s):  
Phase Transformation ◽  
End Milling ◽  
Burr Formation ◽  
Micro End Milling

Effect of Laser Preheating the Workpiece on Micro end Milling of Metals

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
Yongho Jeon ◽  
Frank Pfefferkorn
Keyword(s):  
Yield Strength ◽  
End Milling ◽  
Direct Method ◽  
Burr Formation ◽  
Direct Result ◽  
Transfer Model ◽  
Flexural Stiffness ◽  
Micro End Milling ◽  
End Mills ◽  
Tool Diameter

Micro end milling is a fast and direct method of creating net-shaped functional microparts, micromolds, and prototypes. However, the small flexural stiffness, strength, and hardness of the tool limit the efficiency of machining. It is not expected that a new material with increased hardness and yield strength will be developed in the near future that significantly improves the durability for tools manufactured with diameters in the tens to hundreds of microns. To enable a significant increase in performance and productivity requires higher spindle speeds and increased chiploads. However, an increase in chipload is inhibited by the small flexural stiffness and strength of the tools: a direct result of the tool diameter. Laser-assisted micro end milling has the potential to increase the chipload and productivity by locally reducing the workpiece material’s yield strength at the cutting location. This study examines the effect of laser preheating on micro end milling of 6061-T6 aluminum and 1018 steel. Two-flute, 300μmdia, carbide end mills are used to cut 100μm deep slots at a spindle speed of 40,000rpm. The laser power and chipload are varied to show their effect on cutting forces, specific cutting energy, burr formation, surface finish, and temperature. The results are compared to the average material removal temperature given by predictions made from a heat transfer model of the workpiece undergoing laser preheating. Results indicate that chipload and productivity can be significantly increased during dry machining of 6061-T6 aluminum and 1018 steel by localized preheating of the workpiece.

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