Comparison of Surface Roughness Attainable in High Speed End Milling of Silicon with Air Blowing on Conventional and CNC Milling Machines

2012 ◽  
Vol 576 ◽  
pp. 19-22
Author(s):  
A.K.M. Nurul Amin ◽  
Siti Nurshahida Mohd Nasir ◽  
Noor Syairah Khalid ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Compressed Air ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ductile Mode ◽  
Milling Machines ◽  
Air Blowing ◽  
Machined Surfaces

Review of past research indicated that ductile mode machining of silicon can produce surface roughness values as low as 0.22 µm, which is about half of 0.40 µm, the usual standard roughness value to avoid fine grinding and rough polishing operations. The current research investigated and compared the surface roughness and integrity attained in high speed end milling of silicon (using diamond coated tools) under ductile mode machining conditions. Two different types of end milling machines were utilized, CNC and conventional milling machines. Additionally, the effect of compressed air on the resultant surface roughness was investigated. The air blowing fixture, designed for mounting the compressed air hose, consisted of fixed and movable jaws, air blower clamp, fasteners, and the air gun. Air blowing was used to prevent silicon chips from settling on the machined surface, since it was observed to be an acute problem in high speed ductile mode machining of silicon. The three machining parameters: spindle speed, depth of cut, and feed rate were varied within the ranges 60,000 to 80,000 rpm, 10 to 20 µm, and 5 to 15 mm/min respectively. The resultant machined surfaces were analysed using Wyko NT 1100 and SurfTest SV-500 profilometers in order to measure the attaine surface roughnesses and surface profile. The machined surfaces had almost no deposition and was of excellent finish.

Statistical Approach to Modeling & Optimization of Surface Roughness in High Speed End Milling of Silicon with Diamond Coated Tools

2012 ◽  
Vol 576 ◽  
pp. 28-31 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Noor Syairah Khalid ◽  
Siti Nurshahida Mohd Nasir ◽  
Muammer D. Arif
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
High Speed ◽  
End Milling ◽  
Desirability Function ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Coated Tools ◽  
Milling Machines ◽  
Air Blowing

This research demonstrated the use of conventional milling machines with diamond coated tools, high speed attachments, and air blowing mechanisms for ductile mode machining of silicon and subsequently modeling and optimizing the resultant surface roughness. Spindle speed, depth of cut, and feed rate, ranges: 60,000 to 80,000 rpm, 10 to 20 µm, and 5 to 15 mm/min respectively, were considered as the independent machining parameters for the modeling process. Compressed air at 0.35 MPa was also provided to prevent chip deposition on the finished surfaces. The resultant surfaces were analysed using Optical and Scanning Electron (SEM) Microscopes as well as Wyko NT 1100 and SurfTest SV-500 profilometers. The response, surface roughness, was then modeled using a small Central Composite Design (CCD) in Response Surface Methodology (RSM). The quadratic relation was found to be most suitable following Fit and Summary and ANOVA analyses. The relation was then optimized using Desirability Function (DF) in Design of Expert (DOE) software. The optimum attainable surface roughness, which was validated using experimental runs, was found to be 0.11 µm which may be considered quite satisfactory.

Prediction of Surface Roughness in Compressed Air Jet Assisted High Speed End Milling of Silicon Using Diamond Coated Tools

2012 ◽  
Vol 576 ◽  
pp. 41-45
Author(s):  
A.K.M. Nurul Amin ◽  
M.A. Mahmud ◽  
M.D. Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Surface Finish ◽  
High Speed ◽  
End Milling ◽  
Silicon Wafers ◽  
Compressed Air ◽  
Machining Parameters ◽  
High Quality ◽  
Ductile Mode

The majority of semiconductor devices are made up of silicon wafers. Manufacturing of high-quality silicon wafers includes numerous machining processes, including end milling. In order to end mill silicon to a nano-meteric surface finish, it is crucial to determine the effect of machining parameters, which influence the machining transition from brittle to ductile mode. Thus, this paper presents a novel experimental technique to study the effects of machining parameters in high speed end milling of silicon. The application of compressed air, in order to blow away the chips formed, is also investigated. The machining parameters’ ranges which facilitate the transition from brittle to ductile mode cutting as well as enable the attainment of high quality surface finish and integrity are identified. Mathematical model of the response parameter, the average surface roughness (Ra) is subsequently developed using RSM in terms of the machining parameters. The model was determined, by Analysis of Variance (ANOVA), to have a confidence level of 95%. The experimental results show that the developed mathematical model can effectively describe the performance indicators within the controlled limits of the factors that are being considered.

Optimization of Cutting Parameters in High Speed End Milling of Soda Lime Glass with Coated Carbide Tools Using Directional Compressed Air Blowing

2012 ◽  
Vol 576 ◽  
pp. 111-114
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Compressed Air ◽  
Soda Lime Glass ◽  
Machining Parameters ◽  
Design Expert ◽  
Air Blowing ◽  
Optimization Of Cutting Parameters

An experimental study of high speed machining of soda lime glass using directional compressed air blowing for removal of the ductile chips from the machined surface, is presented. High speed end milling of soda lime glass is performed on a vertical CNC milling machine to observe the effects of machining parameters i.e. spindle speed, depth of cut and feed rate on the resultant surface roughness. The design of the experiments was performed following the Central Composite Design (CCD) of the Response Surface methodology (RSM) using the Design Expert Software. Optimization of machining parameters was conducted using desirability function of the Design Expert software based on minimum surface roughness criterion. Finally, experimental verification tests were conducted to validate the predicted optimized value.

Investigation of the Effects of Machining Parameters and Air Blowing on Surface Topography in High Speed End Milling of Silicon

2012 ◽  
Vol 576 ◽  
pp. 11-14
Author(s):  
A.K.M. Nurul Amin ◽  
Noor Syairah Khalid ◽  
Siti Nurshahida Mohd Nasir ◽  
Muammer D. Arif
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ductile Regime Machining ◽  
Milling Machines ◽  
Air Blowing ◽  
Electron Microscopes ◽  
Machining Parameter

Machining of silicon is an expensive affair because its inherent brittleness leads to subsurface crack generation. Research endeavours have therefore focused on ductile mode machining of silicon to obtain crack free machined surfaces with roughness as low as 0.22 µm or even below, hence eliminating the need for subsequent polishing/grinding operations. However, most of these research works utilized expensive ultraprecision machines and tools. This research aimed at determining the viability of using conventional milling machines with diamond coated tools, high speed attachments, and air blowing mechanisms in order to achieve ductile regime machining of silicon. Spindle speed, depth of cut, and feed rate, ranges: 60,000 to 80,000 rpm, 10 to 20 µm, and 5 to 15 mm/min respectively, were considered as the independent machining parameters. Compressed air at 0.35 MPa was also provided to prevent chip deposition on the finished surfaces. The resultant surfaces were analysed using Optical and Scanning Electron Microscopes. Then, the influence of each machining parameter on surface roughness was investigated. From the analyses it was concluded that all three machining parameters and air blowing had significant influence on the surface topography and integrity of silicon.

Surface Roughness Model for High Speed End Milling of Soda Lime Glass Using Carbide Coated Tools with Compressed Air Blowing

2012 ◽  
Vol 576 ◽  
pp. 107-110
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
Muammer Din Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Gas Turbines ◽  
High Speed ◽  
End Milling ◽  
Soda Lime ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Machining Parameters ◽  
Machined Surface

Glass materials play a vital role in advancement of science and technology. They have found wide spread application in the industry, in laboratory equipment and in micro-gas turbines. Due to their low fracture toughness they are very difficult to machine, moreover there are the chip depositions on the machined surface which affects surface finish under ductile mode cutting conditions. In this research, high speed end milling of soda lime glass is performed on CNC vertical milling machine to investigate the effects of machining parameters i.e. spindle speed, depth of cut, and feed rate on machined surface roughness. Design of experiments was performed following Central Composite Design (CCD) of Response Surface Methodology (RSM). Design Expert Software was used for generating the empirical mathematical model for average surface roughness. The model’s validity was tested to 95% confidence level by Analysis of Variance (ANOVA). Subsequent experimental results showed that the developed mathematical model could successfully describe the performance indicators, i.e. surface roughness, within the controlled limits of the factors that were considered.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

Optimization of Cutting Parameters for High Speed End Milling of Single Crystal Silicon by Diamond Coated Tools with Compressed Air Blowing Using RSM

2012 ◽  
Vol 576 ◽  
pp. 46-50 ◽  
Author(s):  
M.A. Mahmud ◽  
A.K.M. Nurul Amin ◽  
M.D. Arif
Keyword(s):  
Single Crystal ◽  
High Speed ◽  
End Milling ◽  
Single Crystal Silicon ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Crystal Silicon ◽  
Design Expert ◽  
Coated Tools ◽  
Optimization Of Cutting Parameters

This paper presents the thorough experimental analysis on high speed end milling of single crystal silicon using diamond coated tools. Experiments were conducted on CNC milling machine. The design of the experiments was based on the central composite design (CCD) technique of Design Expert software. Response Surface Methodology (RSM) was used to develop mathematical imperial model to establish a correlation between machining parameters (cutting speed, feed and depth of cut) and machined surface roughness in high speed end milling of single crystal silicon using 2mm diameter diamond coated tools. The optimum machining parameters were determined using the optimization tool of Design Expert software based on the desirability function. Finally, confirmation tests were performed to validate the developed model.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

Sign in / Sign up

Export Citation Format

Share Document