scholarly journals Experimental Study on Micro-Grinding of Ceramics for Micro-Structuring

2021 ◽  
Vol 11 (17) ◽  
pp. 8119
Author(s):  
Yung Na ◽  
Ui Seok Lee ◽  
Bo Hyun Kim
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Bottom Surface ◽  
Depth Of Cut ◽  
Generator Circuit ◽  
Machining Of Ceramics ◽  
Micro Tools

In this study, micro-grinding was performed to investigate the machining characteristics of alumina and zirconia. The machining of ceramics remains highly challenging owing to their properties, such as high brittleness and wear resistance, which leads to a shorter tool life and high machining costs. Polycrystalline diamond (PCD) was selected as the tool material, as it is suitable for machining hard and brittle materials, and micro-electrical discharge machining (EDM) was used to fabricate PCD micro-tools. When using a resistor-capacitor generator circuit in micro-EDM, the discharging energy is related to the working capacitance, and by controlling the working capacitance, the different edge radii and the surface roughness of the tool can be easily achieved. The feed rate, depth of cut, and rotation speed were set as experimental parameters to investigate the grinding characteristics of the ceramics. During the experiment, the grinding force and roughness of the bottom surface were monitored, and the roughness of the machined surfaces was measured using a three-dimensional surface profiler. A working capacitance of 1000 pF was used to fabricate a tool with an edge radius of 3.5 µm. The lower radius of the tool edge resulted in a decrease of the cutting force by 50% at most and a surface roughness of 19 nm Ra.

A Truing Technique of Flattening Diamond Grains for Fabricating Microstructures with Fine Surfaces

2008 ◽  
Vol 389-390 ◽  
pp. 350-355
Author(s):  
Takeshi Harada ◽  
Takuya Semba
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Diamond Tool ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
Mesh Size ◽  
Diamond Disk ◽  
Working Surface ◽  
Work Material ◽  
Tool Profile

A truing technique that can be used to shape the tip of an electroformed diamond tool into a hemisphere and flatten diamond grains on the tool working surface at the same level as the bond face was developed. A polycrystalline diamond disk whose top surface roughened by electrical discharge machining was partially flattened by grinding was used as a truer. Diamond grains on the tool working surface were successfully flattened along the hemispherical tool profile when the grains mesh size of #1000 was employed. In addition, a grinding test using glasslike carbon as a work material revealed that a surface roughness of less than 50 nm Rz could be obtained in both cases when moving the tool on contour and scanning paths.

Green-State Micromilling of Additive Manufactured AISI316 L

2019 ◽  
Vol 7 (1) ◽  
Author(s):  
Sandeep Kuriakose ◽  
Paolo Parenti ◽  
Salvatore Cataldo ◽  
Massimiliano Annoni
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Defects ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Force Sensor ◽  
Depth Of Cut ◽  
Green State ◽  
Air Supply ◽  
Wide Range

Additive manufacturing (AM) of metal offers matchless design sovereignty to manufacture metallic microcomponents from a wide range of materials. Green-state micromilling is a promising method that can be integrated into the AM of metallic feedstock microcomponents in typical extrusion-based AM methods for compensating the inability to generate microfeatures. The integration enables the manufacturing of complex geometries, the generation of good surface quality, and can provide exceptional flexibility to new product shapes. This work is a micromachinability study of AISI316 L feedstock components produced by extrusion-based AM where the effects of workpiece temperature and the typical micromilling parameters such as cutting speed, feed per tooth, axial depth of cut, and air supply are studied. Edge integrity and surface roughness of the machined slots, as well as cutting forces, are analyzed using three-dimensional microscopy and piezoelectric force sensor, respectively. Green-state micromilling results were satisfying with good produced quality. The micromilling of heated workpieces (45 °C), with external air supply for debris removal, showed the best surface quality with surface roughness values that reached around Sa = 1.5 μm, much smaller than the average metal particles size. Minimum tendency to borders breakage was showed but in some cases microcutting was responsible of the generation of surface defects imputable to lack of adhesion of deposited layers. Despite this fact, the integrability of micromilling into extrusion-based AM cycles of metallic feedstock is confirmed.

An Experimental Investigation of the Laser Milling Process for Polycrystalline Diamonds

2011 ◽  
Vol 291-294 ◽  
pp. 810-815 ◽  
Author(s):  
Qi Wu ◽  
Jun Wang
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Polycrystalline Diamond ◽  
Milling Process ◽  
Depth Of Cut ◽  
Good Surface ◽  
Laser Milling ◽  
Cavity Profile ◽  
Profile Depth ◽  
Good Surface Finish

An experimental study of the pulsed laser milling process for a sintered polycrystalline diamond is presented. The characteristics and quality of the cavities machined with a Yd laser under different pulse energies, pulse overlaps, scan overlaps and numbers of passes are discussed, together with the effects of these parameters on the cavity profile, depth of cut and surface roughness. A statistical analysis is also presented to study the relationship between the process parameters and surface roughness. It shows that the optimum pulse overlap and pulse energy may be used to achieve good surface finish, whereas scan overlap and number of passes can be selected to improve the depth of cut without much effect on the surface finish.

scholarly journals Machining of Inserts with PCD Cutting-Edge Technology and Determination of Optimum Machining Conditions Based on Roundness Deviation and Chip-Cross Section of AW 5083 AL-Alloy Verified with Grey Relation Analysis

Processes ◽  
2021 ◽  
Vol 9 (9) ◽  
pp. 1485
Author(s):  
Martin Miškiv-Pavlík ◽  
Jozef Jurko
Keyword(s):  
Cross Section ◽  
Feed Rate ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Corner Radius ◽  
Grey Relational

This paper describes the important significance of cutting-edge technology in the machining of polycrystalline diamond (PCD) cutting inserts by comparing the evaluation criteria. The LASER technology of cutting-edge machining is compared with grinding and electrical discharge machining (EDM) technologies. To evaluate the data from the experiments, the Grey Relational Analysis (GRA) method was used to optimize the input factors of turning to achieve the required output parameters, namely the deviation of roundness and chip cross-section. The input factors of cutting speed, feed rate, depth of cut and corner radius were applied in the experiment for three different levels (minimum, medium and maximum). The optimal input factors for turning of aluminum alloy (AW 5083) were determined for the factorial plan according to Grey Relational Grade based on the GRA method for the multi-criteria of the output parameters. The results were confirmed by a verification test according to the GRA method and optimal values of input factors were recommended for the machining of Al-alloy (AW 5083) products. This material is currently being developed by engineers for forming selected components for the automotive and railway industries, mainly to reduce weight and energy costs. The best values of the output parameters were obtained at a cutting speed of 870 m/min, feed rate of 0.1 mm/min, depth of cut of 0.5 mm and a corner radius of 1.2 mm.

A Comparative Study of Machining Parameters on Die-Sinking Electrical Discharge Machining (EDM) using Copper and Aluminium Electrodes on Hard Steels

2016 ◽  
Vol 3 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Ashwani Kharola
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Die Steel ◽  
The Relationship

This paper considers effect of variation in value of Discharge current on different process parameters of Die Sinking EDM. The parameters considered were Material removal rate (MRR), Tool removal rate (TRR), Surface roughness (Ra) and Time (for machining required depth of cut). A total of 32 experiments were conducted on four different hard steels i.e. Die steel D3, En-8, En-19 and Stainless steel (SS-AISI-440C). The Copper and Aluminium electrodes brazed with mild steel were used for machining. The four different values of current i.e. 6A, 9A, 12A and 15A were considered for the study. The experimental results shows the relationship between MRR, TRR, Ra and Time with variation in magnitude of discharge current. This study also illustrates the relationship among different process parameter considered in the study. The results are shown with the help of graphs and tables.

scholarly journals Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

Materials ◽  
2020 ◽  
Vol 13 (24) ◽  
pp. 5677
Author(s):  
Elshaimaa Abdelnasser ◽  
Azza Barakat ◽  
Samar Elsanabary ◽  
Ahmed Nassef ◽  
Ahmed Elkaseer
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Conventional Machining

This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

scholarly journals Effect of Minimum Quantity Lubrication on Surface Roughness and Temperature in Milling of EN31 Steel for Die Making

2019 ◽  
Vol 69 (1) ◽  
pp. 61-68
Author(s):  
Bhosetty Keerthana ◽  
Gurram Vijaya Kumar ◽  
Kumba Anand Babu
Keyword(s):  
Surface Roughness ◽  
Fuzzy Logic ◽  
Particle Swarm Optimization ◽  
Optimization Technique ◽  
Tool Material ◽  
Minimum Quantity Lubrication ◽  
Depth Of Cut ◽  
Swarm Optimization ◽  
Minimum Quantity ◽  
Particle Swarm Optimization Technique

AbstractMinimum Quantity Lubrication has enormous influence on the process parameters in machining. The main aim of the present work is to study the effects of spindle speed, depth of cut, tool material, amount of coolant dispensed and type of coolant on surface roughness and tool temperature in EN31 steel die making including Minimum Quantity Lubrication (MQL) by introducing a self-designed MQL setup and to optimize the responses using fuzzy-logic and Particle Swarm Optimization technique.

scholarly journals Optimization of Machining Parameters on 7075 Aluminum Alloy using Taguchi and ANOVA for Surface Roughness

2020 ◽  
Vol 8 (5) ◽  
pp. 90-95
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Electrical Discharge Machining ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Tool Wear Rate ◽  
Made In

Optimization of the parameter to provide best solution to reduce the tool wear , surface roughness, cutting forces presented using optimization technique .In present work an experimental study is made. In this Taguchi design of experiment methodology for optimization of parameters on 7075Aluminium alloy using tungsten coated electrode . Experiments were conducted based on L27 standard orthogonal array with three processes parameters are cutting speed, feed, depth of cut . Electrical discharge machining is generally calculated on the basis of Surface Roughness (SR),Tool wear rate (TWR) and cutting force (CF) .The ANOVA(Analysis Of Variance) is used to study the performance characteristics in turning operation . ANOVA placed an important role for producing higher roughness . Finally the software ,MINITAB 17 was used and results obtained

Study on EDM Machining Technics of Polycrystalline Diamond Cutting Tool and PCD Cutting Tool’s Life

2011 ◽  
Vol 268-270 ◽  
pp. 309-315 ◽  
Author(s):  
Yun Hai Jia ◽  
Jian Gang Li ◽  
Xue Jun Lu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Machining Parameter ◽  
Diamond Cutting Tool ◽  
The Relationship

The Samples of Polycrystalline Diamond (PCD) Cutting Tool Were Machined by Adjusting the Main Parameters of Electrical Discharge Machining (EDM). after the Machining, the Phases Were Analyzed by X-Ray Diffraction Analyzer and the Surface Layer Microstructure Were Observed by Scanning Electronic Microscope. the Fundamental Component of Machined PCD Cutting Tool Affected Layer Was Obtained and the Reason of Bring Affected Layer Was Analyzed. the Relationship Curves between Pulse Width, Working Electric Current and Depth Affected Layer, Surface Roughness Were Summarized. the Relationship between PCD Cutting Tools that Was Machined by EDM and Cutting Tool Flank Width, Workpiece Surface Roughness Were Analyed.The Results Showed that to Adjust Electical Discharge Machining Parameter, such as Pulse Width and Machining Electric Currents, Can Reduce the Depth of Affect Layer and Extend the Service Life of PCD Cutting Tool.These Researches Provide Valuable Test Reference for Drawing up Electrical Discharge Machining Technics of PCD Cutting Tool and Cutting Tool’s Life.

A Study of the Diamond Tools for Grinding Polycrystalline Diamond

2010 ◽  
Vol 126-128 ◽  
pp. 585-590
Author(s):  
Shenq Yih Luo ◽  
J.K. Ho ◽  
Ming Yi Tsai ◽  
Yi Xian Liu ◽  
William Chen
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
Lower Percentage ◽  
Depth Of Cut ◽  
Workpiece Surface ◽  
Diamond Tools ◽  
Vitrified Bond ◽  
Grinding Efficiency ◽  
Worn Surface

The purpose of this paper was to investigate the grinding performance of two types of cobalt and vitrified bond diamond tools produced by the hot press for the vertical flat grinding polycrystalline diamond. The worn diamond type and the diamond protrusion observed by the toolmaker or SEM after grinding under two different feed rates of 1 and 5 mm/min and the depth of cut of 2 µm with total depth of 10µm were studied. In addition, the grinding efficiency and the workpiece surface roughness produced were analyzed as well. The experiment results showed that when the feed rate of 1 mm/min during the flat grinding PCD was used, a lower percentage of the good diamond, a higher percentage of flat diamond and pulled-out hole on the worn surface of the cobalt bond diamond tool were obtained. For the vitrified bond diamond tool, the good diamond produced showed a higher percentage and flat grit and pulled-out hole displayed a relatively lower percentage. This may be due to the result of the relatively moderate strength and grit retention of the vitrified bond. Furthermore, the diamond protrusion and the grinding efficiency produced for the vitrified bond diamond tool were better than those for the cobalt bond tool. And the PCD surface roughness obtained was better as well.

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