In-process stochastic tool wear identification and its application to the improved cutting force modeling of micro milling

2022 ◽  
Vol 164 ◽  
pp. 108233
Author(s):  
Xuewei Zhang ◽  
Tianbiao Yu ◽  
Pengfei Xu ◽  
Ji Zhao
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Micro Milling ◽  
Force Modeling

Research on Tool Wear of PCD Micro End Mill in Machining of ZrO2 Ceramics

2014 ◽  
Vol 800-801 ◽  
pp. 20-25 ◽  
Author(s):  
Shu Long Wang ◽  
Liang Li ◽  
Ning He ◽  
Rong Bian ◽  
Zhong Bo Zhan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tool ◽  
Micro Milling ◽  
Bottom Surface ◽  
Machining Accuracy ◽  
End Mill ◽  
Micro End Mill ◽  
Wear Tool ◽  
Tool Diameter

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.

Experimental Investigation of the Machinability of Epoxy Reinforced With Graphene Platelets

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Ishank Arora ◽  
Johnson Samuel ◽  
Nikhil Koratkar
Keyword(s):  
Electron Microscopy ◽  
Tool Wear ◽  
Cutting Force ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Micro Milling ◽  
Polymer Phase ◽  
Material Microstructure ◽  
Machined Surface ◽  
Transmission Electron

The objective of this research is to study the effect of graphene platelet (GPL) loading on the machinability of epoxy-based GPL composites. To this end, micro-milling experiments are conducted on composites with varying GPL content and their results are contrasted against that of plain epoxy. The material microstructure is characterized using transmission electron microscopy and scanning electron microscopy methods. Chip morphology, cutting force, machined surface morphology, and tool wear, are employed as the machinability measures for comparative purposes. At lower loadings of GPL (0.1% and 0.2% by weight), the deformation of the polymer phase plays a major role; whereas, at a higher loading of 0.3% by weight, the GPL agglomerates and interface-dominated failure dictates the machining response. The minimum chip thickness value of the composites decreases with an increase in GPL loading. Overall, the 0.2% GPL composite has the highest cutting force and the lowest tool wear.

Experimental Investigation of the Machinability of Epoxy Reinforced With Graphene Platelets

2012 ◽  
Author(s):  
Ishank Arora ◽  
Johnson Samuel ◽  
Nikhil Koratkar
Keyword(s):  
Electron Microscopy ◽  
Tool Wear ◽  
Cutting Force ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Micro Milling ◽  
Polymer Phase ◽  
Material Microstructure ◽  
Machined Surface ◽  
Transmission Electron

The objective of this research is to study the effect of graphene platelet (GPL) loading on the machinability of epoxy-based GPL composites. To this end, micro-milling experiments are conducted on composites with varying GPL content and their results are contrasted against that of plain epoxy. The material microstructure is characterized using transmission electron microscopy and scanning electron microscopy methods. Chip morphology, cutting force, machined surface morphology, and tool wear, are employed as the machinability measures for comparative purposes. At lower loadings of GPL (0.1% and 0.2% by weight) the deformation of the polymer phase plays a major role, whereas at a higher loading of 0.3% by weight, the GPL agglomerates and interface-dominated failure dictates the machining response. The minimum chip thickness value of the composites decreases with an increase in GPL loading. Overall, the 0.2% GPL composite has the highest cutting force and the lowest tool wear.

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.

scholarly journals An Improved Cutting Force Model in Micro-milling Considering the Comprehensive Effect of Tool Runout, Size Effect and Tool Wear

2021 ◽  
Author(s):  
Tongshun Liu ◽  
Yayun Liu ◽  
Kedong Zhang
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Cutting Force ◽  
Cutting Edge ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Tool Runout ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract Tool runout, cutting edge radius-size effect and tool wear have significant impacts on the cutting force of micro-milling. In order to predict the micro-milling force and the machining performance related to the cutting force, it is necessary to establish a cutting force model including tool runout, cutting edge radius and tool wear. In this study, an instantaneous uncut thickness (IUCT) model considering tool runout, a nonlinear shear/ploughing coefficient model including cutting-edge radius and a friction force coefficient model embedded with flank wear width, are constructed respectively. By integrating the IUCT, the nonlinear shear/ploughing coefficient and the friction force coefficient, a comprehensive micromilling force model including the tool runout, size effect and tool wear is derived. Experiment results show that the proposed comprehensive model is efficient to predict the micro milling force.

Experimental Investigation of the Tool Wear and Tool Life in Micro Hard Milling

2013 ◽  
Author(s):  
Shreyas Shashidhara ◽  
Xinyu Liu ◽  
Weihang Zhu ◽  
James Curry ◽  
Victor Zaloom
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Edge Chipping ◽  
Edge Radius

The objective of this project is to experimentally investigate the influence of Minimum Quantity Lubrication (MQL) on tool wear and tool life in micro hardmilling. The experiments were performed on stainless steel using uncoated WC micro-mill with the nominal diameter of 508 microns. The tool wear is characterized by the volume of the material loss at the tool tip. In order to reveal the progression of the tool wear, the worn tool was examined periodically under SEM after a fixed amount of workpiece material removal (1.25 mm3 or 5 slots in this study). The tool life was characterized as the amount of material removed, instead of the conventional cutting times. The feedrate and the spindle speed were fixed, and two levels of axial depth of cut (50 and 75 microns) were compared. The higher depth of cut leads to longer tool life. The machining performance under MQL is superior to the dry machining for both process conditions in terms of the tool life. The cutting forces in feed direction and the surface roughness at the bottom of the slots were also examined during the experiments. The magnitude of the machining forces showed cyclic pattern for both MQL and dry machining. The SEM images and the cutting force signals suggested that the dominant mode of the tool wear in micro-milling is edge chipping and abrasive wear at the tool tip. The loss of the micro-grain of WC at the cutting edge leads to edge chipping, which reduces the effective cutting diameter; the abrasive wear enlarge the edge radius, causing the cutting force increase. As the cutting edge radius reaches a certain dimension, the whole edge was stripped off, a new edge formed with a smaller edge radius, and the cycle restarts. Under MQL cutting conditions, three cycles were observed before tool failure, while under dry machining conditions, the tool only experienced two cycles before tool breakage. The surface roughness at the bottom of the slots improved significantly with the application of MQL for all levels of the tool wear. The surface roughness did not increase drastically as the tool wear increased. It reached a plateau after the tool wear went into gradual wear state. Further experiments and theoretical analysis will be pursued in the future to gain a deeper understanding of tool wear mechanism in micro-milling.

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