The Investigation of a Micro-Component Machined on a Custom-built Miniature Machine Tool

Custom-built Miniature Machine Tools (MMTs) are now becoming more popular with the demand for reduced energy consumption and workshop floor when machining small/medium batch size micro-components. This paper investigates the capability of a custom-built 4-axis MMT through machining an “adapted standard‟ of micro-testpiece. The experiments have been carried out in two different materials: Carbon Steel (AISI 1040) and Titanium Alloyed (TiAl6V4) using solid carbide flat end mill cutters with 0.6mm diameter. From here, the surface quality and geometrical accuracy of the machined testpiece are evaluated and analysed. The investigation has shown that acceptable geometrical accuracies and surface quality of the machined micro-parts can be achieved using the in-house developed MMT. These results show that the use of the custom-made MMT does not hinder the micro-milling process to produce a good and satisfactory surface quality (Ra=0.04-0.07μm) and acceptable geometrical accuracy.

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Machining a Micro-Scale Structure Using an in-House Developed Miniature Machine Tool

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.418-420.1502 ◽

2011 ◽

Vol 418-420 ◽

pp. 1502-1506

Author(s):

Abdul Shukor Syaimak

Keyword(s):

Surface Quality ◽

Machine Tools ◽

Milling Process ◽

Micro Milling ◽

Batch Size ◽

End Mill ◽

Geometrical Accuracy ◽

Custom Made ◽

Solid Carbide

Custom-built Miniature Machine Tools (MMTs) are now becoming more popular with the demand for reduced energy consumption and workshop floor when machining small/medium batch size micro-components. This paper investigates the capability of a custom-built 4-axis MMT through machining a micro-component demonstrator. The experiments have been carried out in Titanium Alloyed (TiAL6V4) using 0.6mm solid carbide flat end mill cutters. From here, the surface quality and geometrical accuracy of the machined testpiece are evaluated and analysed. The investigation has shown that acceptable geometrical accuracies and surface quality of the machined micro-demonstrator can be achieved using the in-house developed MMT. These results show that the use of the custom-made MMT does not hinder the micro-milling process to produce a good and satisfactory surface quality and acceptable geometrical accuracy.

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Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/09544062211013064 ◽

2021 ◽

pp. 095440622110130

Author(s):

Barnabás Zoltán Balázs ◽

Márton Takács

Keyword(s):

Surface Quality ◽

Surface Profile ◽

Cutting Parameters ◽

Relevant Information ◽

Milling Process ◽

Micro Milling ◽

Machined Surface ◽

Analysis Of Dynamics ◽

Five Axis ◽

Coated Carbide

Micro-milling is one of the most essential technologies to produce micro components, but due to the size effect, it has many special characteristics and challenges. The process can be characterised by strong vibrations, relatively large run-out and tool deformation, which directly affects the quality of the machined surface. This paper deals with a detailed investigation of the influence of cutting parameters on surface roughness and on the special characteristics of micro-milled surfaces. Several systematic series of experiments were carried out and analysed in detail. A five-axis micromachining centre and a two fluted, coated carbide micro-milling tool with a diameter of 500 µm were used for the tests. The experiments were conducted on AISI H13 hot-work tool steel and Böhler M303 martensitic corrosion resistance steel with a hardness of 50 HRC in order to gain relevant information of machining characteristics of potential materials of micro-injection moulding tools. The effect of the cutting parameters on the surface quality and on the ratio of Rz/ Ra was investigated in a comprehensive cutting parameter range. ANOVA was used for the statistical evaluation. A novel method is presented, which allows a detailed analysis of the surface profile and repetitions, and identify the frequencies that create the characteristic profile of the surface. The procedure establishes a connection between the frequencies obtained during the analysis of dynamics (forces, vibrations) of the micro-milling process and the characterising repetitions and frequencies of the surface.

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

wt Werkstattstechnik online ◽

10.37544/1436-4980-2015-11-12-45 ◽

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.

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Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

Xibei Gongye Daxue Xuebao/Journal of Northwestern Polytechnical University ◽

10.1051/jnwpu/20183610124 ◽

2018 ◽

Vol 36 (1) ◽

pp. 124-131

Author(s):

Hongji Zhang ◽

Yuanyuan Ge ◽

Hong Tang ◽

Yaoyao Shi ◽

Zengsheng Li

Keyword(s):

Magnesium Alloy ◽

Surface Quality ◽

High Speed ◽

Milling Process ◽

Spindle Speed ◽

Feed Speed ◽

Milling Force ◽

High Speed Milling ◽

Milling Parameters

Within the scope of high speed milling process parameters, analyzed and discussed the effects of spindle speed, feed rate, milling depth and milling width on milling forces in the process of high speed milling of AM50A magnesium alloy. At the same time, the influence of milling parameters on the surface roughness of AM50A magnesium alloy has been revealed by means of the measurement of surface roughness and surface micro topography. High speed milling experiments of AM50A magnesium alloy were carried out by factorial design. Form the analysis of experimental results, The milling parameters, which have significant influence on milling force in high speed milling of AM50A magnesium alloy, are milling depth, milling width and feed speed, and the nonlinear characteristics of milling force and milling parameters. The milling force decreases with the increase of spindle in the given mill parameters. For the effects of milling parameters on surface quality of the performance, in the milling depth and feeding speed under certain conditions with the spindle speed increases the surface quality of AM50A magnesium alloy becomes better with the feed speed increases the surface quality becomes poor. When the spindle speed is greater than 12000r/min, the milling depth is less than 0.2mm, and the feed speed is less than 400mm/min, the milling surface quality can be obtained easily.

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