scholarly journals Research on Parameter Optimization of Micro-Milling Al7075 Based on Edge-Size-Effect

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 197 ◽  
Author(s):  
Yinghua Chen ◽  
Tao Wang ◽  
Guoqing Zhang
Keyword(s):  
Size Effect ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Milling Force ◽  
Milling Tool ◽  
Cutting Parameters Optimization ◽  
Strong Size Effect ◽  
Edge Size

In the process of micro-milling, the appearance of the edge-size-effect of micro-milling tools cannot be ignored when the cutting parameters are smaller than the cutting edge arc radius (r0) of the micro-milling tool or close to it, and it could easily lead to low cutting efficiency and poor surface quality of the micro-slot. Through micro-milling experiments on Al7075-T6 materials, the change of milling force in the plough zone and shear zone during micro-milling was studied, and the minimum cutting thickness (hmin) range was determined to be 0.2r0–0.4r0 based on r0 of the micro-milling tool. Subsequently, the effect of fz/r0 (fz denotes feed rate per tooth) on the top burr formation of the micro-slot, the surface roughness (Ra) of the micro-slot bottom, and the milling force was studied, and a size-effect band of micro milling was established to determine the strong size-effect zone, transition size-effect zone, and the weak size-effect zone. Finally, two different fz/r0 in the strong size-effect zone and the weak size-effect zone are compared, which proves that the main purpose of the cutting parameters optimization of micro-milling is to avoid cutting parameters locating in the strong edge-size-effect zone. The above conclusions provide a theoretical basis for the selection of micro-milling cutting parameters, and an important reference in improving the surface quality of micro-milling.

Experimental Study on Surface Quality in Micro-Milling of Single Crystal Superalloy

2016 ◽  
Vol 1136 ◽  
pp. 196-202
Author(s):  
Qi Gao ◽  
Ya Dong Gong ◽  
Yun Guang Zhou
Keyword(s):  
Single Crystal ◽  
Surface Quality ◽  
Orthogonal Experiment ◽  
Single Crystal Superalloy ◽  
Micro Milling ◽  
Range Analysis ◽  
Milling Tool ◽  
The Impact ◽  
The Ideal

Single crystal Ni3Al-based superalloy has excellent comprehensive performance.To study the micro-milling surface quality of Ni3Al-based superalloy, this article used two-edged carbide alloy micro-milling tool with 0.8mm diameter, then orthogonal experiment of three factors and five levels was implemented to the micro-milling of typical single crystal Ni3Al-based superalloy IC10. The primary and secondary factors of the impact on the micro-milling surface quality were found from spindle speed, feed rate, milling depth by range analysis, and the ideal cutting process parameters combination was optimized and obtained, then its cutting mechanism and the reason of affecting the surface quality were analyzed. The experiment result has certain guiding significance to the micro-milling mechanism of single crystal superalloy.

scholarly journals Study on Surface Roughness in Micro Milling of Single Crystal Materials

2019 ◽  
Vol 1 (1) ◽  
Author(s):  
Qi Gao ◽  
Po Jin ◽  
Guangyan Guo
Keyword(s):  
Surface Roughness ◽  
Single Crystal ◽  
Surface Quality ◽  
Feed Rate ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Micro Milling ◽  
Cemented Carbide Tool

Micro milling is a machining method of high precision and efficiency for micro components and features. In order to study the surface quality of single crystal materials in micro milling, the two-edged cemented carbide tool milling cutter with 0.4 mm diameter was used, and the orthogonal experiment was completed on the micro-milling of single crystal aluminum material. Through the analysis of statistical results, the primary and secondary factor which impacting on surface quality were found as follows: spindle speed, feed rate, milling depth. The ideal combination of optimized process parameters were obtained, when the spindle speed was 36000 r/min, the milling depth was 10 μm, the feed rate was 80 μm/s, which made the milling surface roughness is 0.782 μm and minimal. Single crystal materials removal mechanism were revealed, and the influence of cutting parameters on micro-milling surface were discussed, the reason of tool wear was analyzed. Those provide a certain theoretical and experimental basis for micro milling of single crystal materials.

Realization of ductile regime machining in micro-milling SiCp/Al composites and selection of cutting parameters

2018 ◽  
Vol 233 (12) ◽  
pp. 4336-4347 ◽  
Author(s):  
Junwei Liu ◽  
Kai Cheng ◽  
Hui Ding ◽  
Shijin Chen ◽  
Liang Zhao
Keyword(s):  
Size Effect ◽  
Surface Quality ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Machined Surface ◽  
Side Milling ◽  
Ductile Regime Machining ◽  
Fracture Damage

SiCp/Al composites are widely used owing to their outstanding performance. However, due to the existence of brittle SiC, surface defects caused by particle fracture damage the surface quality severely. Meanwhile, due to small cutting parameters during the micro-milling process, especially the undeformed chip thickness, which is mainly determined by the feed per tooth, the size effect of matrix also damages the surface quality. In this study, a method by realizing the ductile regime machining of the particle and diverting away the defects of particles and matrix is proposed to select the cutting parameters and improve the surface quality in micro-milling SiCp/Al composites. Suitable range of values of the feed per tooth for side milling and end milling are obtained by this method and validated by micro-experiments. The results show that the size effect of Al and removal ways of the SiC particles affect the machined surface simultaneously. By using suitable feed per tooth, weak size effect of Al and most of the particles’ ductile regime removing can be realized, leading to the generation of the best surface. Additionally, the machining effects of this method are more prominent in end milling than in side milling.

A New Method for the Prediction of Micro-Milling Tool Breakage

2017 ◽  
Author(s):  
Xiaohong Lu ◽  
Haixing Zhang ◽  
Zhenyuan Jia ◽  
Yixuan Feng ◽  
Steven Y. Liang
Keyword(s):  
Cutting Parameters ◽  
Ultimate Stress ◽  
New Method ◽  
Micro Milling ◽  
Force Model ◽  
Bending Stress ◽  
Tool Breakage ◽  
Parameters Selection ◽  
Milling Tool ◽  
Milling Force Model

Micro-milling tool breakage has become a bottleneck for the development of micro-milling technology. A new method to predict micro-milling tool breakage based on theoretical model is presented in this paper. Based on the previously built micro-milling force model, the bending stress of the micro-milling cutter caused by the distributed load along the spiral cutting edge is calculated; Then, the ultimate stress of carbide micro-milling tool is obtained by experiments; Finally, the bending stress at the dangerous part of the micro-milling tool is compared with the ultimate stress. Tool breakage curves are drawn with feed per tooth and axial cutting depth as horizontal and vertical axes respectively. The area above the curve is the tool breakage zone, and the area below the curve is the safety zone. The research provides a new method for the prediction of micro-milling tool breakage, and therefore guides the cutting parameters selection in micro-milling.

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 Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

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.

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.

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