Machining of micro features through µ-ECSM process and evaluation of surface integrity

2022 ◽  
Vol 36 ◽  
pp. 45-56
Author(s):  
Nitesh Kumar ◽  
Alok Kumar Das
Keyword(s):  
Surface Integrity ◽  
Micro Features

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

scholarly journals Environmentally sustainable cooling strategies in milling of SA516: Effects on surface integrity of dry, flood and MQL machining

2021 ◽  
Vol 288 ◽  
pp. 125580
Author(s):  
Adam Race ◽  
Iwona Zwierzak ◽  
Jack Secker ◽  
Jonathan Walsh ◽  
Julia Carrell ◽  
...  
Keyword(s):  
Surface Integrity ◽  
Environmentally Sustainable ◽  
Cooling Strategies

scholarly journals The Influence of Blade Type and Feeding Force during Resin Bonded Dentin Specimen Preparation on the Microtensile Bond Strength Test

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 450
Author(s):  
Apinya Limvisitsakul ◽  
Suppason Thitthaweerat ◽  
Pisol Senawongse
Keyword(s):  
Bond Strength ◽  
Surface Integrity ◽  
Strength Test ◽  
Specimen Preparation ◽  
Sectional Area ◽  
Microtensile Bond Strength ◽  
Cross Sectional ◽  
Microtensile Testing ◽  
Feeding Force ◽  
Scanning Electron

This paper presents the effect of blade type and feeding force during resin-bonded dentin specimen preparation on the microtensile bond strength (μTBS) test. Forty resin-bonded flat middle dentin specimens were divided into four groups. The specimens of each group were sectioned according to type of blade and feeding force as follows: fine grit/20 N, fine grit/40 N, medium grit/20 N, and medium grit/40 N to obtain resin-dentin sticks with a cross-sectional area of 1.0 mm2. Four sticks from the center of each tooth were subjected to the μTBS test. Five remaining sticks of each group were selected for surface topography observation under a scanning electron microscope (SEM). As a result, the bond strength of the medium-grit group was higher than that of the fine-grit group (p < 0.001), whereas the feeding force had no influence on bond strength values (p = 0.648). From the SEM, sticks prepared with the fine-grit blade showed a smoother surface integrity and fewer defects on the specimen edges in comparison with the sticks prepared with the medium-grit blade. The grit type of the blade is one of the considerable factors that may affect the bond strength and the surface integrity of resin-dentin specimens for microtensile testing.

scholarly journals FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3789
Author(s):  
Michele Lanzetta ◽  
Marco Picchi Picchi Scardaoni ◽  
Armin Gharibi ◽  
Claudia Vivaldi
Keyword(s):  
Material Properties ◽  
Analytical Modeling ◽  
Cutting Tool ◽  
Sustainable Manufacturing ◽  
Cutting Parameters ◽  
Micro Machining ◽  
Machining Processes ◽  
Steel Alloys ◽  
Diamond Blade ◽  
Micro Features

This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable manufacturing of gecko adhesives by micromachining a durable mold for injection molding. The challenges posed by the mold shape include undercuts and sharp tips, which can be machined by a special diamond blade, which enters the material, forms a chip, and exits. An analytical model to predict the shape of the incipient chip and of the formed grove as a function of the material properties and of the cutting parameters is provided. The main scientific merit of the current work is to approach theoretically, numerically, and experimentally the very early phase of the cutting tool penetration for new sustainable machining and micro-machining processes.

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