Machinability Study of SiC Nano-Particles Reinforced Magnesium Nanocomposites During Micro-Milling Processes

2010 ◽  
Author(s):  
Juan Li ◽  
Jian Liu ◽  
Chengying Xu
Keyword(s):  
Volume Fraction ◽  
High Volume ◽  
Cutting Parameters ◽  
Milling Process ◽  
Spindle Speed ◽  
Nano Particles ◽  
Micro Milling ◽  
Matrix Composites ◽  
Machined Surface ◽  
Machining Productivity

This paper experimentally investigates the machinability of Magnesium Metal Matrix Composites (Mg-MMCs) with high volume fractions of SiC nano-particles. Samples of Mg-MMCs with 5 Vol.%, 10 Vol.% and 15 Vol.% reinforcements of SiC nano-particles were studied and compared with pure Magnesium. Different feedrates and spindle speeds were chosen as varied cutting parameters. Cutting forces, surface morphology and roughness were measured to understand the machinability of the four different materials during the micro-milling process. Based on the experimental results, it is observed that the cutting force increases with the increase of the spindle speed, the feedrate and/or the volume fraction. A drastic increasing rate is observed when the nano-particles’ volume fraction is increased from 5 to 10 Vol.%. The effect of the volume fraction is also studied in frequency domain, combined with the effect of the spindle speed and feedrate. More detailed theoretical analysis will be further studied to better understand the effect of the volume fraction on the machined surface quality and machining productivity.

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.

Investigation on Cutting Forces and Surface Finish in Mechanical Micro Milling of Zr-Based Bulk Metallic Glass

2019 ◽  
Vol 18 (01) ◽  
pp. 113-132
Author(s):  
Debajyoti Ray ◽  
Asit Baran Puri ◽  
Nagahanumaiah
Keyword(s):  
Surface Roughness ◽  
Metallic Glass ◽  
Cutting Force ◽  
Bulk Metallic Glass ◽  
Cutting Parameters ◽  
Milling Process ◽  
Spindle Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Axial Depth

Precision micro-component fabrication demands suitable manufacturing processes that ensure making of parts with good form and finish. Mechanical micro milling represents a flexible and powerful process that exhibits enhanced capability to create micro features. Bulk metallic glass (BMG) represents a young class of amorphous alloy material with superior mechanical and physical properties and finds appreciable micro scale applications like biomedical devices and implants, micro parts for sport items and various other micro- components. In the present work, an attempt has been made to analyze the influence of the cutting parameters like spindle speed, feed per tooth and axial depth of cut on the machinability of BMG, in mechanical micro-milling process. The micro-milling process performances have been evaluated concerning to cutting forces and surface roughness generated, by making full slots on the workpiece with solid carbide end mill cutters. The paper presents micro-machining results for bulk metallic glass machined with commercial micro-milling tool at low cutting velocity regime. Response surface methodology (RSM) has been employed for process modeling and subsequent analysis to study the influence of the combination of cutting parameters on responses within the selected domain of cutting parameters. It has been found that the effect of axial depth of cut on the cutting force components is remarkably significant. Cutting force components increases with the increase in axial depth of cut and decreases with increase in spindle speed. At low feed rate, cutting force in the feed direction (Fx, i.e., cutting force along x-direction) increases with a decrease in feed rate. This increase of force could be due to the possible ploughing effect. A similar pattern of variation has been observed with cutting force component in cross-feed direction (Fy) also. It has been found that effect of feed per tooth on the roughness parameter Ra is remarkably significant. Surface roughness increases with feed per tooth. Axial depth of cut does not contribute much to the surface roughness. Surface roughness decrease with the increase of spindle speed.

Investigation on the Effect of SiC Nanoparticles on Cutting Forces for Micro-Milling Magnesium Matrix Composites

2011 ◽  
Author(s):  
Jian Liu ◽  
Juan Li ◽  
Yingfeng Ji ◽  
Chengying Xu
Keyword(s):  
Cutting Forces ◽  
Volume Fraction ◽  
Elastic Recovery ◽  
Milling Process ◽  
Micro Milling ◽  
Force Model ◽  
Strengthening Effect ◽  
Matrix Composites ◽  
Sic Nanoparticles ◽  
Magnesium Matrix Composites

Magnesium Metal Matrix Composites (Mg-MMCs) with nano-sized reinforcements exhibit better mechanical properties comparing to pure Magnesium (Mg) and its alloys. However, it is challenging to improve the machinability of this kind of composites. An analytical cutting force model for the micro-milling process was developed and validated to analyze the micro-machinability of the SiC nanoparticles reinforced Mg-MMCs. This model is different from the previous ones because it encompasses the behaviors of the reinforcement nanoparticles in the three cutting regimes, i.e., shearing, ploughing and elastic recovery. The volume fraction of particles and particle size are considered as two significant factors affecting the cutting forces in this model. The effects of the reinforcement nanoparticles on cutting forces were studied through modeling and experimental validation. The simulated cutting forces show a good agreement with the experimental data. Moreover, it is indicated that the amplitude and profile of cutting forces vary with the reinforcement particle’s volume fraction. This mainly arises from the strengthening effect of SiC nanoparticles.

Experimental Study on Precision Milling of High Volume Fraction SiCP/Al Composites with PCD End Mills

2013 ◽  
Vol 770 ◽  
pp. 100-105 ◽  
Author(s):  
Qi Wu ◽  
Liang Li ◽  
Rong Bian ◽  
Zhen Yu Shi ◽  
Ning He
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Tool Wear ◽  
Volume Fraction ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
Experimental Result ◽  
Machined Surface ◽  
End Mills

This paper presents an experimental study on precision milling of high volume fraction SiCP/Al composites with single flute polycrystalline diamond (PCD) end mills. Based on a series of tests, the present study is focused on surface roughness of machined surface and tool wear of single flute PCD end mills. The effect of cutting parameters such as feed per tooth (fz) and depth of cut (ap) on the machined surface roughness (Ra) was investigated. Tool wear was also inspected and analyzed by Scanning Electron Microscope (SEM). According to the results of experiment, there is a layer of aluminum covered on the machined surface. This layer of aluminum can improve the machined surface quality. Through the comparsion of surface roughness in different cutting parameters, it can decrease surface roughness (Ra) by means of using very small cutting parameters. Flank wear and chipping are two main kinds of tool wear. The observed wear mechanism of PCD tools is abrasive wear and adhesive wear. The purpose of this study is to provide an experimental result for further investigation on milling of high volume fraction SiCP/Al composites.

Cutting Parameters Impacting on Tool Wear in Micro End-milling of Tool Steel

2018 ◽  
Author(s):  
Cínthia Soares Manso ◽  
Cleiton Lazaro Fazolo de Assis ◽  
Luciana Wasnievski da Silva de Luca Ramos ◽  
Erik Gustavo Del Conte
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Machined Surface ◽  
Tool Diameter

In micro milling process, the quick wear and premature breakage of tools configure a problem that affects not only the process costs but also the manufacturing quality. This work investigates the influence of the cutting parameters on tool wear and surface roughness in a dry machining of a tool steel H13 workpiece (X40CrMoV5-1). Spindle speed was kept constant (27200 rpm) and two feeds per tooth were applied (1.5 and 3.0 µm) as depth of cut (25 and 30 µm), and variating cut length as well. The wear of the tool top area, tool diameter and nose radius were monitored during micro milling tests. Roughness was evaluated by using a Laser Confocal Microscope. The lower level of feed per tooth and depth of cut showed lower roughness, but a higher tool wear. A balance between cutting parameters and cutting length must be considered to ensure micromachining without severe tool wear and preserve microchannel features along its machined surface.

scholarly journals Face Grinding Surface Quality of High Volume Fraction SiCp/Al Composite Materials

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Xu Zhao ◽  
Yadong Gong ◽  
Guiqiang Liang ◽  
Ming Cai ◽  
Bing Han
Keyword(s):  
Friction Coefficient ◽  
Surface Morphology ◽  
Surface Quality ◽  
Volume Fraction ◽  
High Volume ◽  
Spindle Speed ◽  
High Volume Fraction ◽  
Machining Parameters ◽  
Al Composite

AbstractThe existing research on SiCp/Al composite machining mainly focuses on the machining parameters or surface morphology. However, the surface quality of SiCp/Al composites with a high volume fraction has not been extensively studied. In this study, 32 SiCp/Al specimens with a high volume fraction were prepared and their machining parameters measured. The surface quality of the specimens was then tested and the effect of the grinding parameters on the surface quality was analyzed. The grinding quality of the composite specimens was comprehensively analyzed taking the grinding force, friction coefficient, and roughness parameters as the evaluation standards. The best grinding parameters were obtained by analyzing the surface morphology. The results show that, a higher spindle speed should be chosen to obtain a better surface quality. The final surface quality is related to the friction coefficient, surface roughness, and fragmentation degree as well as the quantity and distribution of the defects. Lower feeding amount, lower grinding depth and appropriately higher spindle speed should be chosen to obtain better surface quality. Lower feeding amount, higher grinding depth and spindle speed should be chosen to balance grind efficiently and surface quality. This study proposes a systematic evaluation method, which can be used to guide the machining of SiCp/Al composites with a high volume fraction.

scholarly journals Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4143
Author(s):  
Youzheng Cui ◽  
Shenrou Gao ◽  
Fengjuan Wang ◽  
Qingming Hu ◽  
Cheng Xu ◽  
...  
Keyword(s):  
High Speed ◽  
Large Scale ◽  
Volume Fraction ◽  
Simulation Analysis ◽  
Cutting Temperature ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
High Wear Resistance ◽  
Element Analysis

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc= 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

Study on Machining Mechanism of Glass Using Discrete Element Method

2014 ◽  
Vol 577 ◽  
pp. 108-111 ◽  
Author(s):  
Ying Qiu ◽  
Mei Lin Gu ◽  
Feng Guang Zhang ◽  
Zhi Wei
Keyword(s):  
Discrete Element Method ◽  
Element Model ◽  
Discrete Element ◽  
Rake Angle ◽  
Milling Process ◽  
Micro Milling ◽  
Discrete Element Model ◽  
Machined Surface ◽  
Damage Depth ◽  
Element Method

The discrete element method (DEM) is applied to glass micromachining in this study. By three standard tests the discrete element model is established to match the main mechanical properties of glass. Then, indentating, cutting, micro milling process are simulated. Results show that the vertical damage depth is prevented from reaching the final machined surface in cutting process. Tool rake angle is the most remarkable factor influencing on the chip deformation and cutting force. The final machined surface is determined by the minimum cutting thickness per edge. Different cutting thickness, cutter shape and spindle speed largely effect on the mechanism of glass.

scholarly journals Measurement of Micro Burr and Slot Widths through Image Processing: Comparison of Manual and Automated Measurements

2021 ◽  
Author(s):  
FATIH AKKOYUN ◽  
Ali Ercetin ◽  
Kubilay Aslantas
Keyword(s):  
Image Processing ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Helix Angle ◽  
Milling Process ◽  
Micro Milling ◽  
Inconel 718 Alloy ◽  
Sem Images ◽  
Automated Measurements ◽  
Cutting Length

Abstract In this study, the burr and slot widths formed after micro-milling process are investigated using a rapid and accurate image processing method. The measurements are obtained by processing the images and results were compared with a manual measurement method. In the cutting experiment stage, Inconel 718 alloy was chosen as the workpiece and cutting tools with various specific properties were used. The images of the burr and slots were captured using scanning electron microscope (SEM). Different tool geometries and cutting parameters were considered for choosing the SEM images. Captured images were processed with a computer vision software which was written in C + + programming language and open-sourced computer library (Open CV). The demonstrated approach was successfully measured the slot and burr widths in plain and complex conditions where slot and burr are nested. According to the close findings of manual and automated measurements, it was observed that burr widths increased especially at the down milling sides and slot widths decreased due to the increased cutting length. Specific tool properties such as number of cutting edge, helix angle and cutting length affected the slot and burr widths. It was determined that there is a good correlation between automated and manual measurements of slot and burr widths. The accuracy of the proposed method is above 91%, 98%, and 99% for up milling, down milling, and slot measurements, respectively.

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