Design, optimization and manufacturing of polycrystalline diamond micro-end-mill for micro-milling of GH4169

2020 ◽  
Vol 108 ◽  
pp. 107915 ◽  
Author(s):  
Ni Chen ◽  
Yuan Yuan ◽  
Cheng Guo ◽  
Xinlei Zhang ◽  
Xiuqing Hao ◽  
...  
Micromachines ◽  
2018 ◽  
Vol 9 (11) ◽  
pp. 568 ◽  
Author(s):  
Zhiqiang Liang ◽  
Peng Gao ◽  
Xibin Wang ◽  
Shidi Li ◽  
Tianfeng Zhou ◽  
...  

Tool wear is a significant issue for the application of micro end mills. This can be significantly improved by coating materials on tool surfaces. This paper investigates the effects of different coating materials on tool wear in the micro milling of Ti-6Al-4V. A series of cutting experiments were conducted. The tool wear and workpiece surface morphology were investigated by analyzing the wear of the end flank surface and the total cutting edge. It was found that, without coating, serious tool wear and breakage occurred easily during milling. However, AlTiN-based and AlCrN-based coatings could highly reduce cutting edge chipping and flank wear. Specifically, The AlCrN-based coated mill presented less fracture resistance. For TiN coated micro end mill, only slight cutting edge chipping occurred. Compared with other types of tools, the AlTiN-based coated micro end mill could maximize tool life, bringing about an integrated cutting edges with the smallest surface roughness. In short, the AlTiN-based coating material is recommended for the micro end mill in the machining of Ti-6Al-4V.


2016 ◽  
Vol 1136 ◽  
pp. 143-148 ◽  
Author(s):  
Zhi Qiang Liang ◽  
Li Ping Ma ◽  
Xi Bin Wang ◽  
Wen Xiang Zhao ◽  
Tian Feng Zhou ◽  
...  

This study is carried out to investigate the influence of pulsed magnetic treatment on wear of carbide micro-end-mill. To analyze the friction behavior of micro-end-mill with workpiece, the special micro-end-mill with a chisel is fabricated and used in micro-milling experiments. A paramagnetic material aluminum alloy is employed as workpiece material. The experimental results indicated 17% and 27 % reductions in maximum minor flank wear width and chisel edge wear area of micro-end-mill after pulsed magnetic treatment, respectively. However, the surface roughness and morphology of machined aluminum alloy have no obvious changes with or without pulsed magnetic treatment. Consequently, the reduction of tool wear during milling aluminum alloy can be mainly attributed to the improvement of mechanical properties of carbide tool materials after pulsed magnetic treatment.


2020 ◽  
Vol 167 ◽  
pp. 105277 ◽  
Author(s):  
Y. Sun ◽  
Y.D. Gong ◽  
X.L. Wen ◽  
G.Q. Yin ◽  
F.T. Meng

2014 ◽  
Vol 800-801 ◽  
pp. 20-25 ◽  
Author(s):  
Shu Long Wang ◽  
Liang Li ◽  
Ning He ◽  
Rong Bian ◽  
Zhong Bo Zhan ◽  
...  

This paper presents a study on the tool wear of micro PCD end mill when machining ZrO2 ceramics. The cutting tool used was a self-designed PCD micro end mill with 1 mm in diameter and single flute. Experiments were conducted on a self-developed micro-milling machine tool. The tool wear characters and progress during the groove milling has been observed. The cutting force and machining accuracy of the grooves also have been studied. Based on the results, it is found that tool wear is mainly on the bottom surface; the cutting force increases with the progress of tool wear; tool wear also affect the width of machined grooves due to the decrease of effective tool diameter.


2020 ◽  
Vol 56 ◽  
pp. 169-179
Author(s):  
Ganesh Malayath ◽  
Ajay M. Sidpara ◽  
Sankha Deb

2021 ◽  
Author(s):  
Du Yicong ◽  
Qinghua Song ◽  
Liu Zhanqiang

Abstract When the characteristic structure size of the component is at the micron level, the internal crystal grains, grain boundaries and pore defects of the component material with the same size at the micron level cannot be ignored, so the micro-sized component will show different physical properties from the macro-sized component, which is called size effect. Since the tool diameter of micro-end mill is in the micron level, the micro-end mill will also show a significant size effect phenomenon. In addition, in micro milling process, because the surface roughness that affects the performance and service life of micro parts is mainly influenced by the vibration of micro-end mill, in order to enhance the machined surface quality, it is crucial to research the formation mechanism of surface topography in micro milling process. In this paper, a comprehensive method is proposed to predict micro-end mill vibration, micro milling force and surface roughness. At first, a size-dependent dynamic model of micro-end mill is presented based on the strain gradient elasticity theory (SGET). Secondly, considering the feedback of micro-end mill vibration, the micro milling force model is presented and solved through iterative method. Then the machined surface topography is simulated through the actual cutting edge trajectory considering the micro-end mill size-dependent vibration and material elastic recovery. The results show that the vibration of the micro-end mill will increase the micro milling force and surface roughness. In order to verify the accuracy and efficiency of the presented method, experiments are performed, and it is found that the experimental results are consistent with the predicted results.


2016 ◽  
Vol 693 ◽  
pp. 906-913
Author(s):  
Kai Tao Xu ◽  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Hui Jun Zhou ◽  
Han Lian Liu ◽  
...  

Micro milling is most flexible to create 3D features for application. However, how to design and fabrication of high precision micro milling tools are one of big challenges for mechanical micro milling. Commercially available micro milling tools are usually simply made from downsizing of macro milling tools, which have negative impact on milling performance. Therefore, in this paper, firstly, various structural of micro milling tools were optimized with abaqus that investigated stress and strain under certain static load on the cutting edges. Then, results showed the minimum stress and strain was a micro hexagonal end mill. Finally, a Ti (C7N3) cermet micro hexagonal end mill with a radius of 0.5mm was fabricated by wire electrical discharge machining, and the evaluation experiments for the hexagonal mill have been processed on a micro milling centre.


2018 ◽  
Vol 96 (1-4) ◽  
pp. 1215-1224 ◽  
Author(s):  
Peng Gao ◽  
Zhiqiang Liang ◽  
Xibin Wang ◽  
Shidi Li ◽  
Tianfeng Zhou

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