Surface Profile Analysis in Milling with Structured Tool

2019 ◽  
Vol 13 (1) ◽  
pp. 101-108 ◽  
Author(s):  
Fumihiro Uchiyama ◽  
Akihiko Tsuboi ◽  
Takashi Matsumura ◽  
◽  
◽  
...  
Keyword(s):  
Profile Analysis ◽  
Surface Profile ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Processing Parameters ◽  
Micro Scale ◽  
Surface Finishes ◽  
Optimum Cutting ◽  
End Mills ◽  
Surface Profiles

Novel end mills with micro-scale structures have recently been developed to promote cutting performances with cutting forces, chip controls, and tool wears. However, the surface profiles are formed corresponding to the structures on the tool edges. The surface finishes, therefore, are worse than those of cuttings with straight edges of the end mills. This paper discusses surface profiles in milling with the structured tool and the cutter axis inclination. An analytical model is presented to simulate the surface profiles for the tool edge shape, the cutting parameters and the cutter axis inclination. Because the surface profiles are controlled in the simulation, the optimum cutting parameters are determined to reduce the surface roughness. Micro-scale nicks were fabricated on polycrystalline diamond edges with a laser machine tool. The sizes and pitches of the nicks were controlled by the laser processing parameters. The cutting tests were conducted to measure the surface profiles. The presented surface profile model was validated by comparing the simulated and the measured surface roughnesses. The surface finish can be improved in milling with the cutter axis inclination in the optimum cutting parameters.

Experimental Investigation on Surface Roughness in Precision Cutting Ti6Al4V Alloy Using Diamond Tools

2014 ◽  
Vol 800-801 ◽  
pp. 576-579
Author(s):  
Lin Hua Hu ◽  
Ming Zhou ◽  
Yu Liang Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Limited Range ◽  
Nose Radius ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Titanium Alloy Ti6al4v ◽  
Pcd Tools

In this work, cutting experiments were carried out on titanium alloy Ti6Al4V by using polycrystalline diamond (PCD) tools to investigate the effects of the tool geometries and cutting parameters on machined surface roughness. Experimental results show machined surface roughness decreases with increases in the flank angle, tool nose radius and cutting speed within a limited range respectively, and begins to increase as the factors reaches to certain values respectively. And machined surface roughness decreases with increases in feed rate and cutting depth respectively.

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

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.

scholarly journals A Simple Model to Predict Machined Depth and Surface Profile for Picosecond Laser Surface Texturing

2018 ◽  
Vol 8 (11) ◽  
pp. 2111 ◽  
Author(s):  
Jieyu Xian ◽  
Xingsheng Wang ◽  
Xiuqing Fu ◽  
Zhengwei Zhang ◽  
Lu Liu ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Surface Texturing ◽  
Surface Profile ◽  
Picosecond Laser ◽  
Scanning Speed ◽  
Laser Surface ◽  
Laser Surface Texturing ◽  
Micro Channels ◽  
Surface Profiles ◽  
Simulation Parameters

A simple mathematical model was developed to predict the machined depth and surface profile in laser surface texturing of micro-channels using a picosecond laser. Fabrication of micro-craters with pulse trains of different numbers was initially performed. Two baseline values from the created micro-craters were used to calculate the estimated simulation parameters. Thereafter, the depths and profiles with various scanning speeds or adjacent intervals were simulated using the developed model and calculated parameters. Corresponding experiments were conducted to validate the developed mathematical model. An excellent agreement was obtained for the predicted and experimental depths and surface profiles. The machined depth decreased with the increase of scanning speed or adjacent interval.

scholarly journals Review of Superfinishing by the Magnetic Abrasive Finishing Process

2017 ◽  
Vol 3 (1) ◽  
Author(s):  
Lida Heng ◽  
Yon Jig Kim ◽  
Sang Don Mun
Keyword(s):  
High Surface ◽  
Processing Parameters ◽  
Engineering Industry ◽  
Advanced Materials ◽  
Surface Finishing ◽  
Magnetic Abrasive Finishing ◽  
Surface Finishes ◽  
Abrasive Finishing ◽  
Recent Developments ◽  
Finishing Processes

AbstractRecent developments in the engineering industry have created a demand for advanced materials with superior mechanical properties and high-quality surface finishes. Some of the conventional finishing methods such as lapping, grinding, honing, and polishing are now being replaced by non-conventional finishing processes. Magnetic Abrasive Finishing (MAF) is a non-conventional superfinishing process in which magnetic abrasive particles interact with a magnetic field in the finishing zone to remove materials to achieve very high surface finishing and deburring simultaneously. In this review paper, the working principles, processing parameters, and current limitations for the MAF process are examined via reviewing important work in the literature. Additionally, future developments of the MAF process are discussed.

Surface Quality of Pulsed Laser Cutting of Difficult to Machine Steel

2011 ◽  
Vol 299-300 ◽  
pp. 1016-1019
Author(s):  
Tie Jun Li ◽  
Jing Tang ◽  
Li Jun Yan ◽  
Yang Wang
Keyword(s):  
Surface Quality ◽  
Laser Cutting ◽  
Pulsed Laser ◽  
Cutting Parameters ◽  
Quality Factors ◽  
Good Separation ◽  
Machine Steel ◽  
Optimum Cutting ◽  
Super Alloy

This paper presented the experiments of Nd:YAG pulsed laser cutting of titanium alloy, super-alloy and stainless steel sheet, and investigated the influences of different laser cutting parameters on the surface quality factors focusing surface morphology. In comparison with air-, argon- and nitrogen-assisted laser cutting, argon-assisted laser cutting comes with unaffected surface quality and is suitable for laser cutting with subsequent welding requirement. With analyzing the interaction between pulses overlapping rate and energy, the results show that medium pulse overlapping rate and lower pulse rate helps to improve the surface roughness with pulsed laser cutting. And the results would be beneficial to find optimum cutting parameters for good separation surface.

scholarly journals Pre-evaluation on surface profile in turning process based on cutting parameters

2009 ◽  
Vol 49 (5-8) ◽  
pp. 447-458 ◽  
Author(s):  
Chen Lu ◽  
Ning Ma ◽  
Zhuo Chen ◽  
Jean-Philippe Costes
Keyword(s):  
Surface Profile ◽  
Cutting Parameters ◽  
Turning Process

Surface Profile Analysis for Conformable Interfaces

2003 ◽  
Vol 125 (3) ◽  
pp. 624-627 ◽  
Author(s):  
Mark C. Malburg
Keyword(s):  
Contact Area ◽  
Load Distribution ◽  
Profile Analysis ◽  
Surface Profile ◽  
Solid Surfaces ◽  
Analysis Method ◽  
Uniform Load ◽  
Morphological Filtering ◽  
Novel Method

This paper presents a novel method for the analysis of solid surfaces in contact with a conformable component. These applications are common in many engine and hydraulic applications, wherein conformable seals, gaskets, bushings, etc. are employed to prevent unwanted flow across an interface or provide a uniform load distribution. The proposed analysis method employs a combination of meanline (m-system) filtering and envelope (e-system) or morphological filtering. Through this analysis, a simulation of contact area and the associated voids or gaps can be assessed.

Geometrical consideration for mechanical contact between rolling circle and surface roughness as an improvement to the surface profile

2021 ◽  
Vol 15 (1) ◽  
pp. 7846-7859
Author(s):  
Tsuyoshi Shimizu ◽  
Yasutake Hramiishi ◽  
Takaaki Ishii ◽  
Yuzairi Abdul Rahim ◽  
Mohd Fadzil Ali Ahmad ◽  
...  
Keyword(s):  
Contact Point ◽  
Surface Profile ◽  
Displacement Sensor ◽  
Nose Radius ◽  
Rolling Circle ◽  
Actual Surface ◽  
Contact Type ◽  
Measurement Surface ◽  
Surface Profiles ◽  
Tip Radius

This paper describes measurement methods of surface profiles that improve contact-type displacement sensor outputs by focusing on the contact point between the sphere tip of the sensor and the rough surface. We examined the geometry of a surface profile model and compared measurements using various methods with the measurement using a roughness meter. The spherical tip of the contact type displacement sensor touches the measurement surface and detects the displacement. The sphere tip radius of a typical contact-type displacement sensor ranges from 1–3 mm, causing the roughness curve to be “filtered” by the radius of the sphere.  Three methods for estimating the valley portion of the surface profile are evaluated in this study: a) linear approximation of the concave portion of the surface profile, b) function approximation of the concave portion, and c) using the known nose radius of the machining tool. The following sphere tip radii were used to measure actual surface profiles: 0.25 mm, 0.5 mm, 1.0 mm and 1.5 mm. Given the conditions of the experimental model, we found that surface profiles with a roughness that approximates a predictable curve can be measured with a high degree of accuracy.

Wavelet Transforms in Fractal-Based Form Tolerancing

1993 ◽  
Author(s):  
R. S. Srinivasan ◽  
Kristin L. Wood
Keyword(s):  
Wavelet Transforms ◽  
Design Research ◽  
Profile Analysis ◽  
Synthesis Method ◽  
Surface Profile ◽  
Synthesis Methods ◽  
Geometric Tolerancing ◽  
Analysis And Synthesis ◽  
Cost Implications ◽  
Profile Reconstruction

Abstract Tolerancing is a crucial problem for mechanical designers, as it has quality and cost implications on product design. Research in tolerancing has addressed specific areas of the problem. Building upon previous research, a unified approach for geometric tolerancing with fractal-based parameters has been recently proposed. This paper explores an alternative error profile analysis and synthesis method, based on wavelets, that maintains and extends the use of fractals for surface error abstraction. An overview of the theory of wavelets is provided, and the link between fractals and wavelets is established. Experimental data are used to illustrate the application of wavelet theory to surface profile reconstruction and synthesis. The synthesis methods are then implemented in the design of ball-bearing elements, demonstrating the utility of fractal-based tolerancing. Plans for further study and implementation conclude the paper.

scholarly journals How surface stress transforms surface profiles and adhesion of rough elastic bodies

2020 ◽  
Vol 476 (2243) ◽  
pp. 20200477
Author(s):  
Chung-Yuen Hui ◽  
Zezhou Liu ◽  
Nicolas Bain ◽  
Anand Jagota ◽  
Eric R. Dufresne ◽  
...  
Keyword(s):  
Surface Stress ◽  
Periodic Structures ◽  
Surface Profile ◽  
Initial Surface ◽  
One Dimensional ◽  
Patterned Substrate ◽  
Soft Solids ◽  
Elastic Bodies ◽  
Surface Profiles ◽  
Qualitative Changes

The surface of soft solids carries a surface stress that tends to flatten surface profiles. For example, surface features on a soft solid, fabricated by moulding against a stiff-patterned substrate, tend to flatten upon removal from the mould. In this work, we derive a transfer function in an explicit form that, given any initial surface profile, shows how to compute the shape of the corresponding flattened profile. We provide analytical results for several applications including flattening of one-dimensional and two-dimensional periodic structures, qualitative changes to the surface roughness spectrum, and how that strongly influences adhesion.

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