On the Flexible Abrasive Tool for Nanofinishing of Complex Surfaces

2019 ◽  
Vol 18 (01) ◽  
pp. 157-166 ◽  
Author(s):  
Mithun Sarkar ◽  
V. K. Jain ◽  
Ajay Sidpara
Keyword(s):  
Surface Roughness ◽  
Corrosion Inhibitor ◽  
Abrasive Tool ◽  
End Mill ◽  
Complex Surfaces ◽  
Ball End Mill ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Processing Step ◽  
Finishing Tool

Nanofinishing of complex surfaces is an important but costly processing step for many products for performing their functions satisfactorily. This paper deals with the development of a flexible abrasive tool for nanofinishing of complex surfaces. A flexible finishing tool similar to the ball end mill is developed by curing Polydimethylsiloxane (PDMS). A bowl-shaped copper workpiece is finished to nanometer surface roughness value. Different sizes of abrasive particles are used to reduce surface roughness value of the workpiece. A corrosion inhibitor is mixed with the abrasive slurry to protect the finished copper workpiece surface. A final surface roughness value of 50[Formula: see text]nm has been achieved with a variation up to 70[Formula: see text]nm on different locations of the bowl-shaped workpiece.

Machined Surface Roughness Geometry Model Development on Ultrasonic Vibration Assisted Micromilling with End Mill

2020 ◽  
Vol 846 ◽  
pp. 122-127
Author(s):  
Gandjar Kiswanto ◽  
Yolanda Rudy Johan ◽  
Poly ◽  
Tae Jo Ko
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Model Development ◽  
Cutting Edge ◽  
End Mill ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Geometry Model ◽  
Machined Surface Roughness

Micro products or micro components are commonly used in today’s world. Research around micromanufacture technologies to produce a better product quality has been going on extensively. Ultrasonic vibration assisted micromilling (UVAM) is one of the technologies that can give a better machining qualities over the conventional ones. One of the benefits UVAM can give is reducing the machined surface roughness. The purpose of this paper is to give an idea how vibration assisted micromilling can give a better surface roughness quality. The theoritical surface roughness geometry model is made using MATLAB software. The cutting tool used in the simulation is end mill. There is a feature of the cutting tool called bottom cutting edge angle. This feature will be considered on this paper. The effects of the bottom cutting edge on workpiece machined surface can be looked visually from the simulation. Thus, the effects of cutting process using UVAM on the workpiece surface can be looked as well through the simulation.

Effect of Ground Surface Roughness of Ball End Mill on Cutting Characteristics

2012 ◽  
Vol 565 ◽  
pp. 359-364 ◽  
Author(s):  
Masahiro Furuno ◽  
Koichi Kitajima ◽  
Takeshi Akamatsu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Area ◽  
Ground Surface ◽  
The State ◽  
Cutting Edge ◽  
End Mill ◽  
Ball End Mill ◽  
Ground Surface Roughness ◽  
Flank Surface

The results of an investigation on the effects of surface roughness on ball end mill are reported here. We used grindwheels with varying in grit between #325 and #1000 to grind ball end mill’s rake surface and flank surface, and then coated the end mill with TiAlN film, CrSiN film, and TiSiN film. We measured the state of adhesion on the films on the rake surface in continuous lathe milling as well as the surface roughness and cutting force. The results show that, in generating the cutting cutoff, the optimum grinding roughness differs between the near vicinity of the cutting-edge ridgeline and the part of the rake surface that is further away from the cutting-edge ridgeline. From that fact, we understand that the cutting characteristics of the work material and the surface area of the rake surface that is in contact with the cutting cutoff exert their respective influences during the cutting.

SURFACE TEXTURE ANALYSIS AFTER BALL END MILLING WITH VARIOUS SURFACE INCLINATION OF HARDENED STEEL

2014 ◽  
Vol 21 (1) ◽  
pp. 145-156 ◽  
Author(s):  
Szymon Wojciechowski ◽  
Paweł Twardowski ◽  
Michał Wieczorowski
Keyword(s):  
Surface Roughness ◽  
Inclination Angle ◽  
Surface Texture ◽  
Cutting Speed ◽  
Power Density Spectrum ◽  
End Mill ◽  
Ball End Mill ◽  
Machined Surface ◽  
Surface Irregularities ◽  
Surface Inclination

Abstract In this paper, an analysis of various factors affecting machined surface texture is presented. The investigation was focused on ball end mill inclination against the work piece (defined by surface inclination angle a. Surface roughness was investigated in a 3D array, and measurements were conducted parallel to the feed motion direction. The analysis of machined surface irregularities as a function of frequency (wavelength A), on the basis of the Power Density Spectrum - PDS was also carried out. This kind of analysis is aimed at valuation of primary factors influencing surface roughness generation as well as its randomness. Subsequently, a surface roughness model including cutter displacements was developed. It was found that plain cutting with ball end mill (surface inclination angle a= 0°) is unfavorable from the point of view of surface roughness, because in cutter’s axis the cutting speed vc ~ 0 m/min. This means that a cutting process does not occur, whereas on the machined surface some characteristics marks can be found. These marks do not appear in case of a* 0°, because the cutting speed vc * 0 on the fill I length of the active cutting edge and as a result, the machined surface texture is more homogenous. Surface roughness parameters determined on the basis of the model including cutter displacements are closer to experimental data for cases with inclination angles a* 0°, in comparison with those determined for plain cutting (a= 0°). It is probably caused by higher contribution in surface irregularities generation of plastic and elastic deformations cumulated near the cutter’s free end than kinematic and geometric parameters, as well as cutter displacements.

Manufacture of Micropropellers by Means of Ultraprecision Milling Machine

1997 ◽  
Vol 9 (6) ◽  
pp. 475-479 ◽  
Author(s):  
Yoshimi Takeuchi ◽  
◽  
Kiyoshi Sawada ◽  
Toshio Sata ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Single Crystal ◽  
Rotational Axis ◽  
Milling Machine ◽  
End Mill ◽  
Ball End Mill ◽  
Single Crystal Diamond ◽  
Manufacturing Procedure

The requirement for producing metallic microparts for use in micromachines and/or micromechanisms will continue to increase. This study deals with the manufacturing of tiny parts, of mm-size, using micromachining technology and an ultraprecision milling machine, which consists of a z-motion table, a positionable spindle on it as the c-rotational axis, and an x-motion table. The spindle, which has a pseudo ball end mill composed of a single crystal diamond, is mounted on the x-table. A new manufacturing procedure is devised in order to create a propeller, 3 mm in diameter, as a representative micropart, based on the CAD data of the propeller. As a result, it was found that a functional machined propeller, with a surface roughness of 0.1 μm, can be mounted onto a micromotor shaft, 0.7 mm in diameter.

scholarly journals Mathematical Approach in Complex Surfaces Toolpaths

Mathematics ◽  
2021 ◽  
Vol 9 (12) ◽  
pp. 1360
Author(s):  
Florin Popișter ◽  
Daniela Popescu ◽  
Ancuţa Păcurar ◽  
Răzvan Păcurar
Keyword(s):  
Point Cloud ◽  
Point Clouds ◽  
3D Scanning ◽  
Numerical Control ◽  
Mathematical Approach ◽  
End Mill ◽  
Complex Surfaces ◽  
Ball End Mill ◽  
Scanning Process ◽  
Control Machine

This paper represents the focus on developing efficient algorithms that reduce the operations required to be employed in order to obtain complex surfaces milling finishing toolpaths for the three axis NC (Numerical Control) machine within the reverse engineering chain of processes. Direct machining is the process of generating efficient toolpaths directly from the digitized data, meaning the point cloud. The entire research is focused on determining the mathematical calculus able to interpret the data collected through the contact/noncontact 3D scanning process. In this direction, two algorithms were developed to generate ball-end mill finishing toolpaths for freeform surfaces using ordered/unordered point clouds. Practical work that validates author’s employed algorithms of obtaining finishing milling toolpaths uses the point cloud stored from the 3D scanning process in matrix found in ASCII files, which makes data interpreting easy.

Experimental Research of Effective Cutting Speed Influence on Surface Roughness in Ball End Milling of C45 Material with Hardness 54 HRC

2015 ◽  
Vol 809-810 ◽  
pp. 27-32
Author(s):  
Sandor Ravai-Nagy ◽  
Ioan Paşca ◽  
Mircea Lobontiu ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Curved Surfaces ◽  
End Mill ◽  
Ball End Mill ◽  
Frequent Use ◽  
Optimum Cutting ◽  
End Mills ◽  
The Cost

In the context of the increasingly frequent use of curved surfaces in the design of products surrounding us, ball end mills are at present the only usable tools in the cutting of complex surfaces, either concave or convex. This aspect, once correlated with the need to reduce the surface roughness, which means an increase in the cost of processing, directs our research to those on the milling with ball end mill. In this way we can identify the optimum cutting data in terms of costs to ensure the prescribed surface roughness. The paper is based on a set of experiments on the correlation of roughness with the parameters of the cutting process, for the C45 material treated with heat at 54HRC. The paper presents a part of a complex industrial research in this area and is complementary to the published works [1, 2]

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