Effect of straight and circular tool paths in micro channel fabrication using micro-milling

2021 ◽  
Vol 10 (1) ◽  
pp. 87
Author(s):  
Alwin Varghese ◽  
Suhas S. Joshi
Keyword(s):  
Micro Milling ◽  
Micro Channel ◽  
Tool Paths

A Study on Micro-Milling of Aluminium 6061 and Copper With Respect to Cutting Forces, Surface Roughness and Burr Formation

2018 ◽  
Author(s):  
A. Sravan Kumar ◽  
Sankha Deb ◽  
S. Paul
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
End Milling ◽  
Micro Milling ◽  
Bottom Surface ◽  
Micro Channel ◽  
Al 6061 ◽  
Feed Force ◽  
Micro Channels ◽  
Burr Width

In the present study, micro-milling of aluminium 6061 alloy and copper was undertaken. TiAlN coated two-flute flat end milling cutters of 0.5 mm diameter were used for conducting micro-channel milling experiments with minimum quantity lubrication (MQL) as the cutting environment. The effect of process parameters namely cutting velocity (vc) and feed per flute (fz) on the cutting forces, surface roughness and burr width are reported. RMS values of longitudinal feed force (FX), transverse cutting force (FY) and vertical thrust force (FZ) were measured and the maximum values for Al 6061 are 0.33 N, 0.16 N and 0.21 N respectively, and the same for copper are measured to be 0.11 N, 0.17 N and 0.22 N respectively. Average surface roughness along the milling direction (Ra) at the bottom surface of the micro-channel was measured. Smoother surfaces were generated at lower feed per flute in both the materials. Ra is found to be varying from 28.2 nm to 86.9 nm for Al 6061, and for copper, the range is from 4.9 nm to 32.7 nm. SEM images of the micro-channels were analysed and top burr width was measured in both up-milling and down-milling directions. Higher feed per flute produced smaller burrs in both up-milling and down-milling directions. Maximum burr width for Al 6061 is measured to be 12.86 μm and 15.28 μm in up-milling and down-milling direction respectively, and for copper, the same are measured to be 12.84 μm and 20.46 μm respectively.

Tool wear and remaining useful life prediction in micro-milling along complex tool paths using neural networks

2021 ◽  
Vol 71 ◽  
pp. 679-698
Author(s):  
Sumant Bagri ◽  
Ashish Manwar ◽  
Alwin Varghese ◽  
Soham Mujumdar ◽  
Suhas S. Joshi
Keyword(s):  
Neural Networks ◽  
Tool Wear ◽  
Life Prediction ◽  
Remaining Useful Life ◽  
Micro Milling ◽  
Tool Paths ◽  
Useful Life

Effect of circular tool path on cutting force profile in micro-end-milling

2011 ◽  
Vol 226 (6) ◽  
pp. 1589-1600 ◽  
Author(s):  
A Banerjee ◽  
E V Bordatchev
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Tool Path ◽  
End Milling ◽  
Chip Thickness ◽  
Micro Milling ◽  
Tool Paths ◽  
Chip Formation Mechanism ◽  
Micro End Milling ◽  
Lower Tool

Micro-end-milling requires high spindle rotational speed to achieve effective material removal. This results in the requirement of tool stoppage or slowdown during a micro-end-milling operation, a deterrent to productivity and to part acceptability. A circular tool path geometry can avoid discontinuities in the tool movements leading to a more consistent and smooth material removal. However, optimal process planning for such a tool path will require detailed understanding of the chip-formation mechanism in circular end-milling. The cut geometry during end-milling along a circular tool path is often approximated as that of a linear tool path. Although this assumption works well for circular tool paths with higher tool path radius, this is not the case for lower tool path radius often used in micro-milling. In this study, the effect of circular tool path on the cutting force for varying tool path rotation angle, tool path radius, and feed rate is experimentally investigated. Systematic signal processing was applied to analyse the measured cutting force signal along linear and several circular tool paths. Qualitative as well as quantitative differences were observed in the cutting force profiles obtained using different tool path radii, tool path orientations, and feed rates. This implies the need for an improved chip thickness formulation dedicated to micro-end-milling with circular tool path rather than approximating it with formulations derived for linear tool path.

A study of micro-channel size and spatter dispersion for laser beam micro-milling

2016 ◽  
Vol 32 (2) ◽  
pp. 171-184 ◽  
Author(s):  
Saied Darwish ◽  
Naveed Ahmed ◽  
Abdulrahman M. Alahmari ◽  
Nadeem Ahmad Mufti
Keyword(s):  
Laser Beam ◽  
Micro Milling ◽  
Micro Channel ◽  
Channel Size

Effects of Ion Beam Milling on Surface Topography

1973 ◽  
Vol 31 ◽  
pp. 84-85
Author(s):  
P.G. Pawar ◽  
P. Duhamel ◽  
G.W. Monk
Keyword(s):  
Surface Topography ◽  
Ion Beam ◽  
Solid Material ◽  
Beam Current ◽  
Atomic Mass ◽  
Micro Milling ◽  
Ion Milling ◽  
Controlled Atmospheres ◽  
Milling Operations ◽  
Sufficient Energy

A beam of ions of mass greater than a few atomic mass units and with sufficient energy can remove atoms from the surface of a solid material at a useful rate. A system used to achieve this purpose under controlled atmospheres is called an ion miliing machine. An ion milling apparatus presently available as IMMI-III with a IMMIAC was used in this investigation. Unless otherwise stated, all the micro milling operations were done with Ar+ at 6kv using a beam current of 100 μA for each of the two guns, with a specimen tilt of 15° from the horizontal plane.It is fairly well established that ion bombardment of the surface of homogeneous materials can produce surface topography which resembles geological erosional features.

Detection for Particles Moving in Micro Channel with Multifiber Array Sensor

2012 ◽  
Vol 132 (7) ◽  
pp. 203-211 ◽  
Author(s):  
Ichiro Okuda ◽  
Tomohito Takubo ◽  
Yasushi Mae ◽  
Kenichi Ohara ◽  
Fumihito Arai ◽  
...  
Keyword(s):  
Micro Channel ◽  
Array Sensor
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