scholarly journals Effect of progressive tool wear on the functional performance of micro milling process of injection molding tool

Procedia CIRP ◽  
2020 ◽  
Vol 87 ◽  
pp. 159-163
Author(s):  
Ali Davoudinejad ◽  
Dongya Li ◽  
Yang Zhang ◽  
Guido Tosello
Keyword(s):  
Injection Molding ◽  
Tool Wear ◽  
Functional Performance ◽  
Milling Process ◽  
Micro Milling ◽  
Molding Tool

Schneidkantenpräparation von VHM-Mikrofräsern*/Cutting edge preparation of cemented carbide micro milling tools – A comparison of different fine machining processes

2015 ◽  
Vol 105 (11-12) ◽  
pp. 805-811
Author(s):  
E. Uhlmann ◽  
D. Oberschmidt ◽  
A. Löwenstein ◽  
M. Polte ◽  
I. Winker
Keyword(s):  
Tool Wear ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Machining Processes ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Milling Tools ◽  
Edge Preparation

Die Prozesssicherheit beim Mikrofräsen lässt sich mit einer gezielten Schneidkantenverrundung erheblich steigern. Dabei werden durch verschiedene Präparationstechnologien unterschiedliche Geometrien und Einflüsse auf den Fräsprozess erzeugt. Der Fachbeitrag behandelt den Einsatz präparierter Mikrowerkzeuge in Zerspanversuchen, in denen auf die Zerspankräfte, den Verschleiß sowie die Oberflächengüten eingegangen wird.   Process reliability in micro milling can be increased by a defined cutting edge preparation. Different cutting edge preparations cause different effects on tool behavior in the downstream micro milling process. In this paper, the process forces, the tool wear and the surface quality of prepared micro milling tools are characterized in cutting tests.

Machinability investigation and sustainability analysis of minimum quantity lubrication–assisted micro-milling process

2020 ◽  
Vol 234 (11) ◽  
pp. 1388-1401
Author(s):  
Xueming Yang ◽  
Xiang Cheng ◽  
Yang Li ◽  
Guangming Zheng ◽  
Rufeng Xu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Sustainability Assessment ◽  
Minimum Quantity Lubrication ◽  
Production Quality ◽  
Milling Process ◽  
Micro Milling ◽  
Cutting Fluids ◽  
Thin Wall ◽  
Minimum Quantity

Machining conditions such as cutting fluids exert a crucial function in micro-milling, which removes chips from the cutting area and lubricates the interface between the tool and workpiece. Therefore, it is necessary to identify suitable cutting fluids for processing different materials. In this article, the effects of cutting fluids (dry, flood cooling, minimum quantity lubrication, and jet cold air) on tool wear, surface roughness, and cutting force were studied. The Pugh matrix environmental approach was used to compare different cutting fluids in terms of sustainable production. In addition, a curved thin wall was processed to demonstrate the value of minimum quantity lubrication in industry. The experimental results illustrated that the minimum quantity lubrication can not only effectively reduce tool wear and cutting force but also improve the finished surface quality. According to the sustainability assessment results, minimum quantity lubrication was superior to other cutting fluids in terms of environmental impact and production quality. The curved thin wall size error was only 2.25% under minimum quantity lubrication condition. This indicated minimum quantity lubrication was particularly suitable for micro-milling of H59 brass and 6061 aluminum compared to other cutting fluids.

Experimental Study of Sound Signal for Tool Condition Monitoring in Micro Milling Processes

2008 ◽  
Author(s):  
Chia-Liang Yen ◽  
Ming-Chyuan Lu ◽  
Ching-Yuan Lin ◽  
Tin-Hong Chen
Keyword(s):  
Tool Wear ◽  
Frequency Domain ◽  
High Speed ◽  
Wear Test ◽  
Milling Process ◽  
Micro Milling ◽  
Tool Condition ◽  
Audible Sound ◽  
End Mills ◽  
Speed Up

The audible sound signals obtained in micro-milling processes are analyzed in the time and frequency domain for the tool wear and breakage monitoring. Micro end-mills of φ 700 μm are implemented in the tool wear test, along with a high speed spindle with speed up to 60000 rpm. The audible sound signals and vibration signals for different tool conditions were collected simultaneously in the cutting. After transferring data from time domain to the frequency domain, as well as the Wavelet coefficients, the capability of audible sound signals in detecting the tool condition for the micro milling process was evaluated.

Study of Sound Signal for Tool Wear Monitoring System in Micro-Milling Processes

2009 ◽  
Author(s):  
Tin-Hong Chen ◽  
Ming-Chyuan Lu ◽  
Shean-Juinn Chiou ◽  
Ching-Yuan Lin ◽  
Ming-Hsing Lee
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Milling Process ◽  
Sound Signal ◽  
Micro Milling ◽  
Classifier Systems ◽  
Tool Monitoring ◽  
Micro Tool ◽  
End Mills ◽  
Cutting Processes

The modeling of tool wear effect on micro tool vibration and associated sound generation in the milling process was proposed and analyzed first for sound based micro tool monitoring. The LVQ based algorithms, as well as Fisher Linear Function, were also implemented for verify the sound signal capability for monitoring the tool wear condition in micro milling. Micro end-mills of 700 μm in diameter, a high speed spindle up to 60000 rpm, and sensors were installed to investigate the micro tool wear effect on the cutting system and provide the signals for modeling and system capability verification. Multi-sensor signals including the audible sound, cutting force and vibration were collected simultaneously during cutting processes. The simulation results were compared to experimental results and show good correlation to the collected sound signal. With the training and test sound signals collected in experiment, the classifier systems were established and the capability of sound based system were confirmed for detecting micro tool wear successfully.

The flank wear prediction in micro-milling Inconel 718

2018 ◽  
Vol 70 (8) ◽  
pp. 1374-1380 ◽  
Author(s):  
Xiaohong Lu ◽  
FuRui Wang ◽  
Zhenyuan Jia ◽  
Steven Y. Liang
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Milling Process ◽  
Micro Milling ◽  
Wear Prediction ◽  
Content Type ◽  
Micro Tool

Purpose Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software. Design/methodology/approach Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718. Findings A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously. Originality/value The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

Cutting Parameters Impacting on Tool Wear in Micro End-milling of Tool Steel

2018 ◽  
Author(s):  
Cínthia Soares Manso ◽  
Cleiton Lazaro Fazolo de Assis ◽  
Luciana Wasnievski da Silva de Luca Ramos ◽  
Erik Gustavo Del Conte
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Machined Surface ◽  
Tool Diameter

In micro milling process, the quick wear and premature breakage of tools configure a problem that affects not only the process costs but also the manufacturing quality. This work investigates the influence of the cutting parameters on tool wear and surface roughness in a dry machining of a tool steel H13 workpiece (X40CrMoV5-1). Spindle speed was kept constant (27200 rpm) and two feeds per tooth were applied (1.5 and 3.0 µm) as depth of cut (25 and 30 µm), and variating cut length as well. The wear of the tool top area, tool diameter and nose radius were monitored during micro milling tests. Roughness was evaluated by using a Laser Confocal Microscope. The lower level of feed per tooth and depth of cut showed lower roughness, but a higher tool wear. A balance between cutting parameters and cutting length must be considered to ensure micromachining without severe tool wear and preserve microchannel features along its machined surface.

Tool wear appearance and failure mechanism of coated carbide tools in micro-milling of Inconel 718 super alloy

2016 ◽  
Vol 68 (2) ◽  
pp. 267-277 ◽  
Author(s):  
Xiaohong Lu ◽  
Zhenyuan Jia ◽  
Hua Wang ◽  
Likun Si ◽  
Yongyun Liu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Failure Mechanism ◽  
Inconel 718 ◽  
High Efficiency ◽  
Cutting Tools ◽  
Milling Process ◽  
Micro Milling ◽  
Content Type ◽  
Diffusion Wear ◽  
Coated Carbide

Purpose – The paper aims to study the wear and breakage characteristics of coated carbide cutting tools through micro-milling slot experiments on superalloy Inconel 718. Design/methodology/approach – During the micro-milling process, the wear and breakage appearance on the rake face and flank face of the cutting tools, as well as the failure mechanism, have been studied. Furthermore, the wear and breakage characteristics of the micro-cutting tools have been compared with the traditional milling on Inconel 718. Findings – The main failure forms of the micro tool when micro-milling Inconel 718 were tool tip breakage and coating shed on the rake and flank faces of the cutting tool and micro-crack blade. The main causes of tool wear were synthetic action of adhesive abrasion, diffusion wear and oxidation wear, while the causes of abrasive wear were not obvious. Practical implications – The changing trend in tool wear during the micro-milling process and the main reasons of the tool wear are studied. The findings will facilitate slowing down the tool wear and prolonging the tool life during micro-milling Inconel718. Originality/value – The results of this paper can help slow down the tool wear and realize high efficiency, high precision and economical processing of small workpiece or structure of the nickel-based superalloy.

Sign in / Sign up

Export Citation Format

Share Document