scholarly journals Micro-Milling Process of Metals: A Comparison between Femtosecond Laser and EDM Techniques

2021 ◽  
Vol 5 (4) ◽  
pp. 125
Author(s):  
Luigi Calabrese ◽  
Martina Azzolini ◽  
Federico Bassi ◽  
Enrico Gallus ◽  
Sara Bocchi ◽  
...  
Keyword(s):  
Removal Rate ◽  
Milling Process ◽  
Micro Milling ◽  
Electric Discharge Machining ◽  
Workpiece Material ◽  
Electrically Conductive ◽  
Milling Operations ◽  
Micro Channels ◽  
Micro Pillars

Nowadays, micro-machining techniques are commonly used in several industrial fields, such as automotive, aerospace and medical. Different technologies are available, and the choice must be made considering many factors, such as the type of machining, the number of lots and the required accuracy specifications in terms of geometrical tolerances and surface finish. Lasers and electric discharge machining (EDM) are widely used to produce micro-components and are similarly unconventional thermal technologies. In general, a laser is particularly appreciated by the industry for the excellent machining speeds and for the possibility to machine essentially any type of materials. EDM, on the other hand, has a poor material removal rate (MRR) but can produce microparts on only electrically conductive workpieces, reaching high geometrical accuracy and realizing steep walls. The most common micro-application for both the technologies is drilling but they can make also milling operations. In this work, a comparison of femto-laser and EDM technologies was made focusing on micro-milling. Two features were selected to make the comparison: micro-channels and micro-pillars. The depth was varied on two levels for both features. As workpiece material, aluminum, stainless steel and titanium alloy were tested. Data regarding the process performance and the geometrical characteristics of the features were analyzed. The results obtained with the two technologies were compared. This work improves the knowledge of the micro-manufacturing processes and can help in the characterization of their capabilities.

Fabrication of Tapered Micro Pillars on Titanium Using Electric Discharge Micromachining

2014 ◽  
Author(s):  
V. K. Jain ◽  
Vishnu Suthar ◽  
Anjali V. Kulkarni
Keyword(s):  
Titanium Alloy ◽  
Removal Rate ◽  
Statistical Technique ◽  
Surgical Instruments ◽  
Work Piece ◽  
Chemical Plants ◽  
Electrically Conductive ◽  
Taper Angle ◽  
Micro Pillars ◽  
Pulse On Time

Materials are made harder, tougher, heat resistant and more corrosion resistant which make them difficult-to-machine by traditional machining methods. Titanium and its alloys are in the group of these difficult-to-machine materials, and these alloys have applications in aerospace, power generation, surgical instruments, automobile, chemical plants etc. Ti-6Al-4V is amongst the commonly used titanium alloy, and the current research is focused on its efficient machining. Electro discharge micromachining can be used for producing features in micro range on electrically conductive materials. Straight micro electrodes have been produced using EDMM process. The main objective of the current research is to achieve array of tapered micro pillars on Ti-6Al-4V Work piece material using EDMM process. The effect of process parameters such as gap voltage, discharge current, pulse on-time and duty cycle on the response parameters such as taper angle, material removal rate (MRR) and tool wear rate (TWR) are studied. The experiments are designed using statistical technique. After studying the results of the experiments, the array of micro tapered pillars of different taper angles is produced to see the feasibility of fabrication of tapered pillars on titanium alloy using EDMM process.

A Brief Review of Experimental Investigations and Analytical Development of Powder Mixed Electric Discharge Machining (PMEDM)

2021 ◽  
Vol 106 ◽  
pp. 31-38
Author(s):  
Sovan Bhowmick ◽  
Gautam Majumdar ◽  
Asish Bandyopadhyay
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
White Layer ◽  
Thermal Characteristics ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Machined Surface ◽  
Electrically Conductive ◽  
White Layer Thickness

Powder mixed electric discharge machining (PMEDM) is a newly developed technology in which EDM is performed by mixing electrically conductive micro or nanoparticles with dielectric fluid. The electrically conductive tiny particles when come at the gap of electrode and work piece, they will begin to create spark by the induction of electrode voltage which enhances the material removal and surface finish of the machined surface. In this paper a brief review has been done on different aspects of powder mixed electric discharge machining. It is observed that the researches are done in three main directions. Firstly, experimental studies are done to show the effect of several input process parameters on responses mainly material removal rate (MRR), surface roughness and tool wear rate. Secondly, the metallurgical characteristics of the machined surface are analyzed to measure the white layer thickness and amount of powder material inclusion onto the surface. The third one is the investigation of thermal characteristics of the tool and work pieces during the machining process. In these three sections of researches, the results of the investigations have been discussed in this review. Keywords: powder mixed electric discharge machining, metallurgical characteristics, nano particles, material removal rate, surface roughness, tool wear rate, white layer thickness, thermal characteristics

A Mechanistic Model for the Prediction of the Force System in Face Milling Operations

1984 ◽  
Vol 106 (1) ◽  
pp. 81-88 ◽  
Author(s):  
H. J. Fu ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Mechanistic Model ◽  
Polycrystalline Diamond ◽  
Milling Process ◽  
Face Milling ◽  
Workpiece Material ◽  
Material Force ◽  
Force System ◽  
Milling Operations ◽  
The Face ◽  
Casting Aluminum

A mechanistic force system model for the face milling process has been developed and implemented on the computer. The model predicts the force system in face milling over a range of cutting conditions, cutter geometries, workpiece, and process geometries including relative positions of cutter to workpiece, spindle tilt, and runout. Machining tests have been conducted for both fly cuting and multitooth cutting with polycrystalline diamond tools on plain surfaces. The 390 casting aluminum alloy has been used as the workpiece material. Force data from these tests were used to estimate the empirical constants of the mechanistic model and to verify its prediction capabilities. Data bases from flycutting tests have been used to predict forces under multitooth face milling and the results indicate good agreement with observed data from multitooth tests.

Experimental Analysis of Laser Micro-Machining Process Parameters

2012 ◽  
Vol 713 ◽  
pp. 67-72
Author(s):  
Daniel Teixidor ◽  
I. Ferrer ◽  
Joaquim de Ciurana
Keyword(s):  
Process Parameters ◽  
Laser System ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Surface Finishing ◽  
Features Selection ◽  
Operational Parameters ◽  
Micro Channels ◽  
Hardened Tool Steel

This paper reports the characterization of laser machining (milling) process to manufacture micro-channels in order to understand the incidence of process parameters on the final features. Selection of process operational parameters is highly critical for successful laser micromachining. A set of designed experiments is carried out in a pulsed Nd:YAG laser system using AISI H13 hardened tool steel as work material. Several micro-channels have been manufactured as micro-mold cavities varying different process parameter. Results are obtained by evaluating the dimensions and the surface finish of the micro-channel. The dimensions and shape of the micro-channels produced with laser-micro-milling process exhibit variations. In general the use of low scanning speeds increases the quality of the feature in both surface finishing and dimensional.

Machining Parameters Mapping’s of Inconel 718 and Aluminum Alloy 1100 in Micro-Milling Process

2020 ◽  
Vol 846 ◽  
pp. 99-104
Author(s):  
Gandjar Kiswanto ◽  
Maulana Azmi ◽  
Adrian Mandala ◽  
Dede Lia Zariatin ◽  
Tae Jo Ko
Keyword(s):  
Aluminum Alloy ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Machining Parameters ◽  
Workpiece Material

The development of micro-products in industry, like aviation, medical equipment, electronics, etc, has been increasing lately. The need for scaling down of product has been increasing to make the product simpler and complex. Micro-milling has capabilities in producing complex parts. In this study, mapping and comparing the result of the machining process of Inconel 718 and Aluminum Alloy 1100 was employed. In this experiment, Inconel 718 was used as workpiece material and the result of Aluminum Alloy taken from recent studies. Then, A cutting tool with a diameter 1 mm carbide coating TiAlN was used in this experiment. The machining process was performed with three varieties of spindle speed and feed rate with a constant depth of cut. After the machining is done, the mapping of the result surface roughness of Inconel 718 and AA1100 performed. It was found that Inconel 718 has poor machinability compared with AA 1100. Inconel 718 also has a high manufacturing cost compared to AA 1100 because the cutting tool was easy to wear.

scholarly journals Temperature Distribution of Micro Milling Process due to Uncut Chip Thickness

2014 ◽  
Vol 939 ◽  
pp. 214-221 ◽  
Author(s):  
B.T.H.T. Baharudin ◽  
Kooi Pin Ng ◽  
S. Sulaiman ◽  
R. Samin ◽  
M.S Ismail
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Model Validation ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Micro Milling ◽  
Work Piece ◽  
Workpiece Material ◽  
Undeformed Chip Thickness

A simplified model for micro milling process is presented, as well as results on temperature on tool and work piece. The purpose is to investigate on finite element modelling of two flute micro end milling process of titanium alloy, Ti6Al4V with prediction of temperature distribution. ABAQUS/Explicit has been chosen as solver for the analysis. A thermo-mechanical analysis was performed. First model was created by selecting medium carbon steel, AISI1045, as workpiece material for model validation purpose. Second model was created by modifying the workpiece material from AISI1045 to Ti6Al4V. The model consists of two parts which are tungsten carbide micro tool and workpiece. Johnson-Cook law model has been applied as material constitutive properties for both materials due to its severe plastic deformation occur during machining. Prediction on forces was obtained during the analysis. Model validation was done by comparing results published by Woon et al. in 2008. The results showed a good agreement in cutting force. Once this was proved, the same model was then modified to simulate finite element analysis in micro milling of Ti6Al4V. Prediction of temperature distribution of micro end mill of Ti6Al4V was done in relation of different undeformed chip thickness. The findings showed that temperature increases as undeformed chip thickness increases. Temperature distribution of Ti6Al4V and AISI1045 under same machining conditions was compared. Results showed that the highest temperature was concentrated at tool edge for Ti6Al4V.

Optimization of Micro-Milling Process with Genetic Algorithm

2011 ◽  
Vol 383-390 ◽  
pp. 7111-7116 ◽  
Author(s):  
Neng Hsin Chiu ◽  
Guo Ting Weigh
Keyword(s):  
Genetic Algorithm ◽  
Prediction Model ◽  
Computer Program ◽  
Tool Life ◽  
Removal Rate ◽  
Milling Process ◽  
Micro Milling ◽  
Feasible Range ◽  
Key Techniques ◽  
Dual Objectives

As miniaturization of product becomes a trend, meso-machining technique for relevant components becomes necessary. Micro- milling with small size cutter is one of the key techniques for meso-manufacturing. When size of tool becomes small, feasible range of process parameter becomes limited. Without properly selected parameter, it could result in cost increase and quality unacceptable. Optimization of micro-milling to maximize removal rate and tool life is an important issue. This study aims at developing an optimization module using genetic algorithm for micro-milling. A milling experiment for constructing a prediction model of tool life was conducted. A computer program based on Pareto genetic algorithm was coded to search for optimized solution. A set of non-dominated solution satisfying dual objectives was obtained as the result. The solution can be used for determining milling parameter based on process interest.

Chatter Stability in Micro Milling Processes Considering Ploughing and Process Damping Effects

2009 ◽  
Author(s):  
Ramin Rahnama ◽  
Mozhdeh Sajjadi ◽  
Simon S. Park
Keyword(s):  
Time Domain ◽  
Chip Thickness ◽  
Experimental Tests ◽  
Micro Milling ◽  
Chatter Stability ◽  
Workpiece Material ◽  
Process Damping ◽  
Milling Operations ◽  
Milling Operation ◽  
Cutting Mechanisms

Micro milling operations utilize miniature tools to remove workpiece material, in order to create the desired 3D miniature components. One of the challenges in a micro milling operation is the unstable phenomenon called regenerative chatter. The occurrence of chatter in the micro domain, as in macro machining, is detrimental to part finishes and significantly reduces the longevity of tools. There are two different cutting mechanisms in micro milling operations, which are determined by the critical chip thickness. When the chip thickness is less than the critical chip thickness, no chip forms and ploughing occurs; whereas, when the chip thickness is greater than the critical chip thickness, a chip forms and shearing cutting happens. During each rotation of the tool, the cutting mechanisms switch from ploughing to shearing and vice versa. This paper introduces a time domain chatter model to investigate the effects of the ploughing and shearing mechanisms on stability. The model also considers the effects of process damping in micro milling, especially at low spindle speeds. Several experimental tests have been performed to validate the model.

Virtual Simulation and Optimization for 5-Axis Milling Process

2010 ◽  
Vol 102-104 ◽  
pp. 754-757 ◽  
Author(s):  
Li Qiang Zhang
Keyword(s):  
Cutting Forces ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Milling Process ◽  
Physical Models ◽  
Free Form ◽  
Surface Machining ◽  
Simulation And Optimization ◽  
Feedrate Optimization ◽  
Milling Operations

5-axis milling operations are used in industries such as aerospace, automotive and mold for free-form surface machining. In these process, surface quality and material removal rate are of very important. Conservative cutting parameters have been mostly used since there was a lack of physical models and optimization tools. Part and tool deflections under high cutting forces may result in unacceptable part quality. The overall goal of this research is the integration of geometric and mechanistic models for cutting process simulation and feedrate optimization. The extracted cutter workpiece engagements are used as input to a force prediction model. The model predictions for cutting forces and feedrate optimization are compared and verified by experimental results.

scholarly journals Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

Materials ◽  
2019 ◽  
Vol 12 (6) ◽  
pp. 907 ◽  
Author(s):  
Jaber Abu Qudeiri ◽  
Ahmad Saleh ◽  
Aiman Ziout ◽  
Abdel-Hamid Mourad ◽  
Mustufa Abidi ◽  
...  
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Future Research ◽  
Process Conditions ◽  
Process Performance ◽  
Electric Discharge Machining ◽  
Electrically Conductive ◽  
Complex Shapes ◽  
Efficient Manufacturing

Electric discharge machining (EDM) is a material removal process that is especially useful for difficult-to-cut materials with complex shapes and is widely used in aerospace, automotive, surgical tools among other fields. EDM is one of the most efficient manufacturing processes and is used to achieve highly accurate production. It is a non-contact thermal energy process used to machine electrically conductive components irrespective of the material’s mechanical properties. Studies related to the EDM have shown that the process performance can be considerably improved by properly selecting the process material and operating parameters. This paper reviews research studies on the application of EDM to different grades of stainless steel materials and describes experimental and theoretical studies of EDM that have attempted to improve the process performance, by considering material removal rate, surface quality and tool wear rate, amongst others. In addition, this paper examines evaluation models and techniques used to determine the EDM process conditions. This review also presents a discussion on developments in EDM and outlines the likely trend for future research.

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