Surfaces Machined by Micro End-Mills at Constant Chip Load

2010 ◽  
Vol 443 ◽  
pp. 232-237 ◽  
Author(s):  
Jong Leng Liow ◽  
Ulrich Frye
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Edge ◽  
End Mill ◽  
Single Pass ◽  
End Mills ◽  
Secondary Cutting ◽  
Chip Load

The surfaces of Al6061, machined by 150 μm two flute micro end-mills, were studied to determine their roughness. The surface roughness, Ra, was less than 100 nm but the Ra/Rz ratio ranged from 0.03–0.12. The surface roughness was found to improve with increasing width of cut and to a lesser extent with increasing feed rate. A single pass of the end-mill was found to produce a smoother surface than two passes over the same surface. The surface roughness was found to correspond to the diameter of the end mill and the slope of the secondary cutting edge. To reduce the surface roughness, smaller diameter end mills and chip loads should be used.

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.

scholarly journals Optimization of Boring Process Parameters in Manufacturing of Polyacetal Bushing using High Speed Steel

2019 ◽  
Vol 130 ◽  
pp. 01031 ◽  
Author(s):  
The Jaya Suteja ◽  
Yon Haryono ◽  
Andri Harianto ◽  
Esti Rinawiyanti
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Optimum Result ◽  
Edge Angle

Polyacetal is commonly used as bushing material because of its low coefficient of friction and self lubricant characteristics. The polyacetal is machined by using boring process to produce bushing in certain surface roughness. The objectives of this research are to optimize three independent parameters (depth of cut, feed rate and principal cutting edge angle) of boring process of polyacetal using high speed steel tool to achieve the highest material removal rate and the required surface roughness. Response Surface Methodology is used to investigate the influence of the parameters and optimize the boring process. The research shows that the influence of the boring process parameters on polyacetal is similar compared to on metal. The result reveals that the optimum result is achieved by applying the value of depth of cut, feed rate, and principal cutting edge angle is 2.9 × 10–3 m, 0.229 mm rev–1, and 99.1° respectively. By applying these values, the maximum material rate removal achieved in this research is 1263.4 mm3 s–1 and the surface roughness achieved is 1.57 × 10–6 m.

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.

The Predictive Model of Surface Roughness and Searching System in Database for Cutting Tool Grinding

2009 ◽  
Vol 626-627 ◽  
pp. 11-16 ◽  
Author(s):  
Yung Cheng Wang ◽  
Chen Hsiang Chen ◽  
Bean Yin Lee
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Rapid Development ◽  
Cutting Tools ◽  
Experiment Planning ◽  
Grinding Wheel ◽  
End Mill ◽  
Grinding Parameters ◽  
End Mills ◽  
Tool Grinding

Due to the rapid development in recent cutting technology, demands for different types of precise cutting tools become increasingly complicated. Since the design and grinding of end-mills are the last and the most important processing for cutting tools. The geometrical accuracy and the cutting performance of an end-mill depend essentially on the grinding. However, the complicated geometry of an end-mill will be ground by the specific software of CAD/CAM on the 5-axis CNC tool grinding machine. The precision of end-mill grinder will be determined by the performance of 5-axis CNC tool grinder and setting of grinding parameters. Three regulation factors for grinding are grit size of the diamond grinding wheel, grinding speed and the feeding speed. The variable ranges of each parameter can be divided in large, medium and small interval. In this study for an end-mill with fixed geometrical profile, a series of different grinding parameters have been utilized by the 33 factorial experiment planning. And tool grinding experiments for the rod material specification of tungsten carbide have been performed by 5-axis CNC tool grinder. After grinding, surface roughness of tools will be measured. The reliability and precision of the end-mill grinding can be enhanced by the prediction model of polynomial network for surface roughness of end-mills. Besides, the database system for cutting tool has benn established. Totally 4802 data were constructed in the relational database according to the characteristics of tools.

scholarly journals Surface roughness of thermally treated wood cut with different parameters in CNC router machine

BioResources ◽  
2021 ◽  
Vol 16 (3) ◽  
pp. 5133-5147
Author(s):  
Hüseyin Pelit ◽  
Mustafa Korkmaz ◽  
Mehmet Budakçı
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Treatment Temperature ◽  
Spindle Speed ◽  
Numerical Control ◽  
Machining Parameters ◽  
End Mill ◽  
Cnc Machine ◽  
Cnc Router ◽  
Thermally Treated

The effects of different machining parameters on surface roughness values of thermally treated pine, beech, and linden woods cut in a computer numerical control (CNC) router machine were examined. Wood specimens were thermally treated at 170, 190, and 210 °C for 2 h. Then, specimens were cut in the radial and tangential directions with three different spindle speeds (12000, 15000, and 18000 rpm) and three different feed rates (3000, 4000, and 6000 mm/min) using two different end mill tools (spiral and straight) on the CNC machine. The end mill type significantly affected the roughness values of the untreated and thermally treated specimens in both directions. Lower roughness values were found in the specimens (especially pine) machined with the straight end mill compared to those machined with the spiral end mill. Roughness generally decreased in the thermally treated specimens. However, thermal treatment temperature did not have a notable effect on roughness. As the spindle speed increased, the roughness values of all specimens decreased. In contrast, as the feed rate increased, the roughness values increased. Therefore, the end mill type, feed rate, and spindle speed were the most influential parameters on the roughness.

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.

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.

5-Axis Control Dexterous Ultraprecision Micromilling of Ruled Surface with Side Cutting Edge

2012 ◽  
Vol 516 ◽  
pp. 176-180
Author(s):  
Ryo Nishiyama ◽  
Keiichi Nakamoto ◽  
Tohru Ishida ◽  
Yoshimi Takeuchi
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Ruled Surface ◽  
Cutting Edge ◽  
Work Piece ◽  
End Mill ◽  
Ball End Mill ◽  
Tool Paths ◽  
End Mills ◽  
Quality Surface

This study deals with 5-axis control tool path generation to create microshapes dexterously and efficiently, while maintaining quality. Concerning 5-axis control machining, the use of ball end mills is generally employed. However, this method needs a lot of time to obtain high quality surface. To solve this problem, a side cutting edge of the ball end mill is positively utilized with its parallel to the ruled surface. Therefore, a new CAM system is developed to detect the surface to be machined with the side cutting edge, and to generate collision-free tool paths between the tool and the work piece. The effectiveness of the developed CAM system is experimentally confirmed by creating a tiny Möbius ring.

scholarly journals Analysis of Abrasives On Cutting Edge Preparation By Drag Finishing

2021 ◽  
Author(s):  
Dejin Lv ◽  
Yongguo Wang ◽  
Xin Yu ◽  
Han Chen ◽  
Yuan Gao
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Material Removal ◽  
Cutting Edge ◽  
K Factor ◽  
Solid Carbide ◽  
End Mills ◽  
Cutting Edge Preparation ◽  
Drag Finishing ◽  
Edge Preparation

Abstract Cutting edge preparation has become more important for tool performance. The micro-shape, radius and surface topography of the cutting edge plays a significant role in the machining process. The cutting edge of solid carbide end mills have some micro-defects after grinding. For eliminating aforementioned problem, this study investigates drag finishing (DF) preparation for solid carbide end mills reconstruct cutting edge micro-geometry. This paper is to present the design of DF experimental set-up and analysis the characterization of various abrasive media (K3/600, K3/400, HSC 1/300 and HSO 1/100) on the evolution of the surface /roughness along the cutting edge. In parallel, the mechanism of material removal and the kinematics trajectory of the drag finishing are presented. In fact, the form factor (also called as “K-factor”) of the cutting edge micro-geometry is quantified. Comparing with four lapping media, the higher material removal rate (MRR) and the lower surface roughness are obtained by HSO 1/100 abrasive process. The results show that the cutting edge K-factor, MRR and surface topography are influenced by the abrasive particles size, composition and process time. The cutting edge micro-geometry is measured through Scanning Electron Microscopy (SEM) and 3D Optical measuring instrument.

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