scholarly journals Investigation of the Effect of End Mill-Geometry on Roughness and Surface Strain-Hardening of Aluminum Alloy AA6082

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3078
Author(s):  
Pavel Filippov ◽  
Michael Kaufeld ◽  
Martin Ebner ◽  
Ursula Koch
Keyword(s):  
Surface Roughness ◽  
Strain Hardening ◽  
Cutting Edge ◽  
Surface Strain ◽  
Micro Milling ◽  
End Mill ◽  
Cutting Edge Radius ◽  
Hardened Zone ◽  
Edge Radius ◽  
Machined Surfaces

Micro-milling is a promising technology for micro-manufacturing of high-tech components. A deep understanding of the micro-milling process is necessary since a simple downscaling from conventional milling is impossible. In this study, the effect of the mill geometry and feed per tooth on roughness and indentation hardness of micro-machined AA6082 surfaces is analyzed. A solid carbide (SC) single-tooth end-mill (cutting edge radius 670 nm) is compared to a monocrystalline diamond (MD) end-mill (cutting edge radius 17 nm). Feed per tooth was varied by 3 μm, 8 μm and 14 μm. The machined surface roughness was analyzed microscopically, while surface strain-hardening was determined using an indentation procedure with multiple partial unload cycles. No significant feed per tooth influence on surface roughness or mechanical properties was observed within the chosen range. Tools’ cutting edge roughness is demonstrated to be the main factor influencing the surface roughness. The SC-tool machined surfaces had an average Rq = 119 nm, while the MD-tool machined surfaces reached Rq = 26 nm. Surface strain-hardening is influenced mainly by the cutting edge radius (size-effect). For surfaces produced with the SC-tool, depth of the strain-hardened zone is higher than 200 nm and the hardness increases up to 160% compared to bulk. MD-tool produced a thinner strain-hardened zone of max. 60 nm while the hardness increased up to 125% at the surface. These findings are especially important for the high-precision manufacturing of measurement technology modules for the terahertz range.

Investigation on Mechanism of Ultra-Smoothed Surface with a Micro Slot on the Flank Face in Micro Cutting

2014 ◽  
Vol 651-653 ◽  
pp. 764-767
Author(s):  
Tao Zhang ◽  
Hou Jun Qi ◽  
Gen Li
Keyword(s):  
Surface Roughness ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Back Side ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Flank Face ◽  
Side Flow

Micro cutting is a promising manufacturing method to obtain good surface integrity. Surface roughness shows size effect when the uncut chip thickness is smaller than the cutting edge radius. A special micro slot on the flank face of cutting tools was manufactured with discharge. Two groups of micro orthogonal cutting were conducted. The surface roughness of machined surface was measured and compared to each other. The results show that surface roughness decreases first and then increases with the ratio of uncut chip thickness to cutting edge radius. The surface machined with micro slot is better than that of without micro slot due to the micro slot restrain the back side flow of work piece based on the finite element model.

scholarly journals An Improved Cutting Force Model in Micro-milling Considering the Comprehensive Effect of Tool Runout, Size Effect and Tool Wear

2021 ◽  
Author(s):  
Tongshun Liu ◽  
Yayun Liu ◽  
Kedong Zhang
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Cutting Force ◽  
Cutting Edge ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Tool Runout ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract Tool runout, cutting edge radius-size effect and tool wear have significant impacts on the cutting force of micro-milling. In order to predict the micro-milling force and the machining performance related to the cutting force, it is necessary to establish a cutting force model including tool runout, cutting edge radius and tool wear. In this study, an instantaneous uncut thickness (IUCT) model considering tool runout, a nonlinear shear/ploughing coefficient model including cutting-edge radius and a friction force coefficient model embedded with flank wear width, are constructed respectively. By integrating the IUCT, the nonlinear shear/ploughing coefficient and the friction force coefficient, a comprehensive micromilling force model including the tool runout, size effect and tool wear is derived. Experiment results show that the proposed comprehensive model is efficient to predict the micro milling force.

Kryogenes Drehen von X6CrNiNb18-10*/Cryogenic turning of AISI 347 - Impact of the cutting edge radius on mechanical load and surface integrity

2018 ◽  
Vol 108 (01-02) ◽  
pp. 14-19
Author(s):  
H. Hotz ◽  
B. Kirsch ◽  
S. Gutwein ◽  
S. Becker ◽  
E. von Harbou ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Hardening ◽  
Mechanical Load ◽  
Cutting Edge ◽  
Machining Process ◽  
Micro Hardness ◽  
Cutting Edge Radius ◽  
Metastable Austenitic Steel ◽  
Edge Radius ◽  
Cryogenic Turning

Metastabile austenitische Stähle bieten die Möglichkeit einer in den Zerspanprozess integrierten Randzonenverfestigung. Im Fachartikel wird zunächst der Einfluss des Schneidkantenradius auf die Prozesskräfte untersucht. Anschließend werden die daraus resultierenden Auswirkungen auf die verformungsinduzierte Martensitbildung in der Werkstückrandzone untersucht sowie die erzeugten Werkstücke hinsichtlich Mikrohärte und Rauheit verglichen.   Metastable austenitic steel enables direct surface hardening during the machining process. In this article, the influence of the cutting edge radius on process forces, as well as the effect on the martensitic phase transformation are investigated. The generated workpieces are examined with regard to micro hardness and surface roughness.

scholarly journals Investigation on the size effect in micro end milling considering the cutting edge radius and the workpiece material

2021 ◽  
Vol 12 (1) ◽  
pp. 487-499
Author(s):  
Yang Li ◽  
Xiang Cheng ◽  
Guangming Zheng ◽  
Huanbao Liu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Chip Morphology ◽  
Cutting Edge ◽  
Workpiece Material ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Element Simulation ◽  
Cutting Experiment ◽  
Cutting Mechanisms

Abstract. Previous research has found that the peripheral and end cutting edges of the cutter had different cutting mechanisms in the micro end cutting process considering the size effect. This investigation is a further study on this point considering the cutting edge radius of the cutter and the material of the workpiece based on the methods of finite element simulation and the micro end cutting experiment. This study adopts a combination of simulation and experiment research methods and the cutting edge radius and the workpiece material as two variables. Considering the cutting mechanisms of the peripheral cutting edge and the end cutting edge are different, the peripheral cutting edge and the end cutting edge are studied respectively. Meanwhile, the minimum undeformed chip thickness (MUCT) value is determined in three ways, chip morphology, cutting force, and surface roughness, so the final result obtained by comparing three kinds of results has a very important reference value. Not only are the chip morphology obtained by finite element simulation and the surface roughness obtained by the micro end cutting experiment used to identify the MUCT value, but also the cutting force. The simulation and experimental results show that the cutting force can be used to identify the MUCT value for the peripheral cutting edge, but it cannot be used for the end cutting edge. The MUCT value increases with the increase of the cutting edge radius, no matter which process it is. The material property has some effects on the MUCT value; even the cutting parameters and the cutting edge radius remain unchanged for the peripheral cutting edge. However, the material property has no effect on the MUCT value for the end cutting edge. In this study, the influence of important variables on MUCT is studied as much as possible to reflect a real application situation.

Effects of Tool Nose Corner Radius and Main Cutting-Edge Radius on Cutting Temperature in Micro-Milling Inconel 718 Process

2017 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Likun Si ◽  
Steven Y. Liang
Keyword(s):  
Three Dimensional ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Milling Cutter ◽  
Micro Scale ◽  
Cutting Edge Radius ◽  
Corner Radius ◽  
Edge Radius

Cutting temperature plays an important role in micro-scale cutting process because the dimension of the micro-milling cutter is relatively small and the wear of micro-milling cutter is sensitive to temperature. Considering the sidewall of a groove is formed by main cutting edge of the tool, and the bottom of a groove is formed by tool tip and the edge on the end of the tool. Therefore, effects of tool nose corner radius and main cutting edge radius on cutting temperature in micro-milling process cannot be ignored. However, few studies have been conducted on this issue. The effects of tool nose corner radius and main cutting edge radius on cutting temperature is investigated. A three-dimensional micro-milling Inconel718 model is established by using the software DEFORM3D. And the influence of tool nose corner radius and main cutting edge radius on the size and distribution of cutting temperature are studied by numerical simulation, which is verified by experiments. The work provide reference for the control of the size and distribution of the cutting temperature during micro-milling process.

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