scholarly journals Cutting Performance of Different Coated Micro End Mills in Machining of Ti-6Al-4V

Micromachines ◽  
2018 ◽  
Vol 9 (11) ◽  
pp. 568 ◽  
Author(s):  
Zhiqiang Liang ◽  
Peng Gao ◽  
Xibin Wang ◽  
Shidi Li ◽  
Tianfeng Zhou ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Edge ◽  
Micro Milling ◽  
End Mill ◽  
Coating Materials ◽  
Edge Chipping ◽  
Workpiece Surface ◽  
Micro End Mill ◽  
End Mills ◽  
Flank Surface

Tool wear is a significant issue for the application of micro end mills. This can be significantly improved by coating materials on tool surfaces. This paper investigates the effects of different coating materials on tool wear in the micro milling of Ti-6Al-4V. A series of cutting experiments were conducted. The tool wear and workpiece surface morphology were investigated by analyzing the wear of the end flank surface and the total cutting edge. It was found that, without coating, serious tool wear and breakage occurred easily during milling. However, AlTiN-based and AlCrN-based coatings could highly reduce cutting edge chipping and flank wear. Specifically, The AlCrN-based coated mill presented less fracture resistance. For TiN coated micro end mill, only slight cutting edge chipping occurred. Compared with other types of tools, the AlTiN-based coated micro end mill could maximize tool life, bringing about an integrated cutting edges with the smallest surface roughness. In short, the AlTiN-based coating material is recommended for the micro end mill in the machining of Ti-6Al-4V.

Research on Tool Wear of PCD Micro End Mill in Machining of ZrO2 Ceramics

2014 ◽  
Vol 800-801 ◽  
pp. 20-25 ◽  
Author(s):  
Shu Long Wang ◽  
Liang Li ◽  
Ning He ◽  
Rong Bian ◽  
Zhong Bo Zhan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tool ◽  
Micro Milling ◽  
Bottom Surface ◽  
Machining Accuracy ◽  
End Mill ◽  
Micro End Mill ◽  
Wear Tool ◽  
Tool Diameter

This paper presents a study on the tool wear of micro PCD end mill when machining ZrO2 ceramics. The cutting tool used was a self-designed PCD micro end mill with 1 mm in diameter and single flute. Experiments were conducted on a self-developed micro-milling machine tool. The tool wear characters and progress during the groove milling has been observed. The cutting force and machining accuracy of the grooves also have been studied. Based on the results, it is found that tool wear is mainly on the bottom surface; the cutting force increases with the progress of tool wear; tool wear also affect the width of machined grooves due to the decrease of effective tool diameter.

Schneidkantenpräparation von VHM-Mikrofräsern*/Cutting edge preparation of cemented carbide micro milling tools – A comparison of different fine machining processes

2015 ◽  
Vol 105 (11-12) ◽  
pp. 805-811
Author(s):  
E. Uhlmann ◽  
D. Oberschmidt ◽  
A. Löwenstein ◽  
M. Polte ◽  
I. Winker
Keyword(s):  
Tool Wear ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Machining Processes ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Milling Tools ◽  
Edge Preparation

Die Prozesssicherheit beim Mikrofräsen lässt sich mit einer gezielten Schneidkantenverrundung erheblich steigern. Dabei werden durch verschiedene Präparationstechnologien unterschiedliche Geometrien und Einflüsse auf den Fräsprozess erzeugt. Der Fachbeitrag behandelt den Einsatz präparierter Mikrowerkzeuge in Zerspanversuchen, in denen auf die Zerspankräfte, den Verschleiß sowie die Oberflächengüten eingegangen wird.   Process reliability in micro milling can be increased by a defined cutting edge preparation. Different cutting edge preparations cause different effects on tool behavior in the downstream micro milling process. In this paper, the process forces, the tool wear and the surface quality of prepared micro milling tools are characterized in cutting tests.

Machined Surface Roughness Geometry Model Development on Ultrasonic Vibration Assisted Micromilling with End Mill

2020 ◽  
Vol 846 ◽  
pp. 122-127
Author(s):  
Gandjar Kiswanto ◽  
Yolanda Rudy Johan ◽  
Poly ◽  
Tae Jo Ko
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Model Development ◽  
Cutting Edge ◽  
End Mill ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Geometry Model ◽  
Machined Surface Roughness

Micro products or micro components are commonly used in today’s world. Research around micromanufacture technologies to produce a better product quality has been going on extensively. Ultrasonic vibration assisted micromilling (UVAM) is one of the technologies that can give a better machining qualities over the conventional ones. One of the benefits UVAM can give is reducing the machined surface roughness. The purpose of this paper is to give an idea how vibration assisted micromilling can give a better surface roughness quality. The theoritical surface roughness geometry model is made using MATLAB software. The cutting tool used in the simulation is end mill. There is a feature of the cutting tool called bottom cutting edge angle. This feature will be considered on this paper. The effects of the bottom cutting edge on workpiece machined surface can be looked visually from the simulation. Thus, the effects of cutting process using UVAM on the workpiece surface can be looked as well through the simulation.

High-Quality End Milling of CFRP – Inclination Milling with High-Helix End Mill –

2016 ◽  
Vol 10 (3) ◽  
pp. 372-380 ◽  
Author(s):  
Akira Hosokawa ◽  
◽  
Naoya Hirose ◽  
Takashi Ueda ◽  
Tomohiro Koyano ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Integrity ◽  
Helix Angle ◽  
Surface Generation ◽  
End Mill ◽  
Side Milling ◽  
Pull Out ◽  
End Mills ◽  
Coated Carbide

Side milling tests of CFRP (carbon fiber reinforced plastics) containing thermosetting resin are carried out by TiAlN/AlCrN-coated, H2-free DLC (diamond-like carbon)-coated, and CVD diamond-coated carbide end mills without coolant. Two types of end mills having different helix angles of 30° and 60° are used. The film thickness and surface smoothness are varied for the DLC-coated end mills. The cutting characteristics are evaluated by tool wear and surface integrity (i.e., 3D profiles of the machined surface, generation of fluffing, delamination, and pull-out of the carbon fibers). The cutting force and tool flank temperature are also examined for the two types of CFRP composites and the helix angle of the end mill. “Inclination milling,”in which the end mill is tilted so that the resultant cutting force acts parallel to the work surface, is proposed as a novel technique to be used with a high-helix angle end mill. This unique approach enables the reduction of tool wear and improves the surface integrity of machined CFRP surfaces.

Influence of Pulsed Magnetic Treatment on Wear of Carbide Micro-end-Mill

2016 ◽  
Vol 1136 ◽  
pp. 143-148 ◽  
Author(s):  
Zhi Qiang Liang ◽  
Li Ping Ma ◽  
Xi Bin Wang ◽  
Wen Xiang Zhao ◽  
Tian Feng Zhou ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Magnetic Treatment ◽  
Micro Milling ◽  
End Mill ◽  
Friction Behavior ◽  
Workpiece Material ◽  
Wear Area ◽  
Paramagnetic Material ◽  
Micro End Mill ◽  
Edge Wear

This study is carried out to investigate the influence of pulsed magnetic treatment on wear of carbide micro-end-mill. To analyze the friction behavior of micro-end-mill with workpiece, the special micro-end-mill with a chisel is fabricated and used in micro-milling experiments. A paramagnetic material aluminum alloy is employed as workpiece material. The experimental results indicated 17% and 27 % reductions in maximum minor flank wear width and chisel edge wear area of micro-end-mill after pulsed magnetic treatment, respectively. However, the surface roughness and morphology of machined aluminum alloy have no obvious changes with or without pulsed magnetic treatment. Consequently, the reduction of tool wear during milling aluminum alloy can be mainly attributed to the improvement of mechanical properties of carbide tool materials after pulsed magnetic treatment.

Tool Wear Characters in Micro-Milling of Fully Sintered ZrO2 Ceramics by Diamond Coated End Mills

2012 ◽  
Vol 723 ◽  
pp. 365-370 ◽  
Author(s):  
Rong Bian ◽  
Eleonora Ferraris ◽  
Jun Qian ◽  
Dominiek Reynaerts ◽  
Liang Li ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Tools ◽  
Chemical Vapour ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Machined Surface ◽  
Coated Tools ◽  
Machined Surface Quality ◽  
Coating Delamination ◽  
End Mills

This work presents an experimental investigation on micro-milling of fully sintered Zirconia (ZrO2) by diamond coated tools. The experiments were conducted on a Kern MMP 2522 micro-milling centre and WC micro end mills, diamond coated by chemical vapour deposition (CVD) and of stiff geometry were employed as cutting tools. The effects of cutting parameters and milling time on tool wear were investigated. The results revealed that the tool wear characters included diamond coating delamination and wear of substrate WC. Both cutting forces and machined surface quality were affected by tool wear with the progress of milling.

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.

Micro milling characteristics of LS-WEDM fabricated helical and corrugated micro end mill

2020 ◽  
Vol 167 ◽  
pp. 105277 ◽  
Author(s):  
Y. Sun ◽  
Y.D. Gong ◽  
X.L. Wen ◽  
G.Q. Yin ◽  
F.T. Meng
Keyword(s):  
Micro Milling ◽  
End Mill ◽  
Micro End Mill ◽  
Milling Characteristics

Effect of Ground Surface Roughness of Ball End Mill on Cutting Characteristics

2012 ◽  
Vol 565 ◽  
pp. 359-364 ◽  
Author(s):  
Masahiro Furuno ◽  
Koichi Kitajima ◽  
Takeshi Akamatsu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Area ◽  
Ground Surface ◽  
The State ◽  
Cutting Edge ◽  
End Mill ◽  
Ball End Mill ◽  
Ground Surface Roughness ◽  
Flank Surface

The results of an investigation on the effects of surface roughness on ball end mill are reported here. We used grindwheels with varying in grit between #325 and #1000 to grind ball end mill’s rake surface and flank surface, and then coated the end mill with TiAlN film, CrSiN film, and TiSiN film. We measured the state of adhesion on the films on the rake surface in continuous lathe milling as well as the surface roughness and cutting force. The results show that, in generating the cutting cutoff, the optimum grinding roughness differs between the near vicinity of the cutting-edge ridgeline and the part of the rake surface that is further away from the cutting-edge ridgeline. From that fact, we understand that the cutting characteristics of the work material and the surface area of the rake surface that is in contact with the cutting cutoff exert their respective influences during the cutting.

Study of different materials response in micro milling using four edged micro end mill tools

2020 ◽  
Vol 56 ◽  
pp. 169-179
Author(s):  
Ganesh Malayath ◽  
Ajay M. Sidpara ◽  
Sankha Deb
Keyword(s):  
Micro Milling ◽  
End Mill ◽  
Micro End Mill
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