Experimental Investigation on the Milling Performance of a 50 μm D-Shaped Micromilling Cutter with Different Materials

Abstract In micromilling, the performance and diameter of the milling cutter directly determine the service life of the milling cutter and the surface quality of the microgroove. Therefore, it is vital for high-precision milling to explore the milling performance of different materials and expand the application scope of micromilling cutter sizes. In this study, the milling performance of three kinds of material cutters—carbide, diamond coating and polycrystalline diamond (PCD)—was evaluated. A series of micromilling tests were carried out to determine the effects of cutter material type on cutter wear, surface quality and burr formation, particularly when a 50 µm micromilling cutter was used in the milling process. A D-shaped milling cutter with a diameter of 50 µm was manufactured on a self-developed high-precision modular machine tool by wire electrode electric discharge grinding (WEDG) technology. From theoretical and experimental perspectives, it is easy to master microgroove quality milled by different material cutters. The results show that the microgrooves processed with PCD cutters have fewer burrs, lower surface roughness values, and a smoother groove bottom morphology.

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

Jurnal Teknologi ◽

10.11113/jt.v59.2563 ◽

2012 ◽

Vol 59 (2) ◽

Author(s):

Syaimak Abdul Shukor

Keyword(s):

Surface Quality ◽

Milling Process ◽

Micro Milling ◽

Batch Size ◽

Geometrical Accuracy ◽

Custom Made ◽

Micro Parts ◽

Solid Carbide ◽

Steel Aisi

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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The Influence of Process Parameters and Scanning Strategy on Lower Surface Quality of TA15 Parts Fabricated by Selective Laser Melting

Metals ◽

10.3390/met10091228 ◽

2020 ◽

Vol 10 (9) ◽

pp. 1228

Author(s):

Junjie Jiang ◽

Jianming Chen ◽

Zhihao Ren ◽

Zhongfa Mao ◽

Xiangyu Ma ◽

...

Keyword(s):

Surface Quality ◽

Selective Laser Melting ◽

Process Parameters ◽

Flexible Manufacturing ◽

Molten Pool ◽

Lower Surface ◽

Laser Melting ◽

Scanning Strategy ◽

Influence Of Process Parameters

With superior flexible manufacturing capability, selective laser melting (SLM) has attracted more and more attention in the aerospace, medical, and automotive industries. However, the poor quality of the lower surface in overhanging structures is still one of the factors that limits the wide application of SLM. In this work, the influence of process parameters and scanning strategy on the lower surface quality of SLMed TA15 (Ti-6Al-2Zr-1Mo-1V) titanium alloy parts were studied. The results showed that the laser surface energy density (EF) had a significant influence on the quality of the lower surface. Excessive EF led to obvious sinking of the molten pool and a serious slag hanging phenomenon. However, the too low EF easily contributed to the insufficient powder fusion in the lower surface area, which led to the agglomeration of a molten pool during core processing, resulting in slag hanging, pores, and powder spalling that reduced the quality of the lower surface. Moreover, the cross-remelting strategy and non-remelting strategy gained better surface quality at the low EF and high EF, respectively. In addition, it was found that the quality of the lower surface could be quickly and accurately evaluated by the cooling time of the molten pool during the processing of the lower surface. This research can increase the understanding of the forming mechanism of the lower surface and has certain guiding significance for the process optimization of the lower surface.

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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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Surface quality of carbon/carbon composite after ultrasonic assisted turning

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405410396131 ◽

2011 ◽

Vol 225 (11) ◽

pp. 2144-2148 ◽

Cited By ~ 2

Author(s):

F J Ma ◽

D M Guo ◽

R K Kang ◽

Y J Ren

Keyword(s):

Surface Quality ◽

Evaluation Method ◽

Diamond Tool ◽

Polycrystalline Diamond ◽

Carbon Composite ◽

Distribution Characteristics ◽

Good Surface ◽

Ultrasonic Assisted ◽

Machining Defect

It is usually hard to obtain a good surface quality of carbon/carbon (C/C) composite by turning due to its non-homogeneity and anisotropy. Contrasting experiments of ultrasonic assisted turning (UAT) and common turning (CT) of the C/C composite were carried out using a polycrystalline diamond tool. The cylindrical surface of the turning was classified into four typical types based on different fibre orientations. The influence of fibre distribution characteristics on surface roughness was analysed by measuring and comparing the roughness of these surfaces, and an evaluation method of surface quality for the C/C composite after turning was established. The results of UAT experiments on the C/C composite show that UAT could effectively reduce the machining defect. The roughness of typical surfaces 1 and 2 machined using UAT was about 20 per cent lower than that using CT.

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Study on Boring Small Hole of Stainless Steel Dryly by Ultrasonic Vibration Double Cutter

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.490-495.1551 ◽

2012 ◽

Vol 490-495 ◽

pp. 1551-1554

Author(s):

Jian Zhong Zhang ◽

Xin Wang ◽

Yue Zhang

Keyword(s):

Stainless Steel ◽

Surface Quality ◽

High Precision ◽

Ultrasonic Vibration ◽

Cutting Temperature ◽

Small Hole ◽

Dry Cutting ◽

Shape Precision ◽

Process System

It has been one of the difficulties that high-precision small hole on stainless steel is machined. The supersonic vibration boring acoustic system is installed in the lathe. The supersonic wave energy applies to tool to create pulse power on the cutting process. The separation vibration cutting is achieved by the pulse force. The comparative tests on boring surface quality are carried. The quality of surface machined by this method is compared to that by grinding. This cutting is the green cutting. The boring process system is stability. The cutting force is greatly reduced. The cutting temperature is at room temperature. The tool life is greatly increased. Surface quality and shape precision is greatly improved. The regulations of the ultrasonic vibration boring dry cutting of stainless steel are also summarized. The test results show that the ultrasonic vibration boring by double cutter is of very superior cutting mechanism and is a high-precision thin - long deep - hole machining of stainless steel materials, efficient cutting methods.

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Investigation of Surface Quality in Cost of Goods Manufactured (COGM) method of µ-Al2O3 Powder-Mixed-EDM Process on Machining of Ti-6Al-4V

10.21203/rs.3.rs-297047/v1 ◽

2021 ◽

Author(s):

Aboulfazl Taherkhania ◽

Mohsen Asghari Ilani ◽

Faramarz Ebrahimi ◽

Phan Huu Nguyen ◽

Long Banh Tien ◽

...

Keyword(s):

Surface Quality ◽

Lower Surface ◽

Dielectric Medium ◽

Dielectric Fluid ◽

Powder Concentration ◽

Surface Oxides ◽

Micron Size ◽

Deep Cavities ◽

Edm Process

Abstract It is very essential to form such high stregth and hard-to-cut materials by using modern machining methods. It is important to introduce the efforts on modification of the process for improving the machining quality. In the present investigation, an effort was made to analyze the effects of micro size aluminium particles mixed dielectric medium under different powder concentration on machining titanium alloy in electro erosion process. The response-surface-methodology(RSM) based algorithm was utilized to analyze the performance measures by considering machinning time with Cost of Goods Manufactured (COGM) method in PMEDM process. It was found that the micron size powders can significantly help to enhance the surface quality of the Ti-6Al-4V surface during machining in EDM process. The presence of carbon, oxygen elements and the formation of surface oxides and carbides has been found due to the decomposition of dielectric fluid in PMEDM process. The lower deep cavities and uniform machining surface have been produced with the aluminum oxide powder EDM process owing to lower surface cracks density, conductivity. To sum up, investigation and comparison of surface scanning showed that this setting has been implied could be considered by the industries needs more precision.

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