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.

Evaluation of Surface Quality and Signal Characteristics in Milling Process of Al7075-T651

2017 ◽  
Vol 737 ◽  
pp. 95-100
Author(s):  
M.C. Hwang ◽  
Joon Young Koo ◽  
Yong Ki Choi ◽  
Hyun Jung Kim ◽  
Jeong Suk Kim
Keyword(s):  
Aluminum Alloys ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Milling Process ◽  
Signal Frequency ◽  
Burr Formation ◽  
Machined Surface ◽  
Specific Strength ◽  
Multiple Sensors ◽  
Signal Characteristics

Recently, as the automotive and aerospace industry research has focused one weight lightening, the use of functional aluminum alloys has been increasing. Aluminum alloys are effective materials because of their high specific strength and high stiffness ratio. However, machining deformation and heat deflection can occur depending on the machining type. Owing to these difficult-to-cut characteristics, it is necessary to monitor the machined surface quality of aluminum alloys. In this paper, we study the correlation between surface quality, namely burr formation and surface roughness, related to cutting parameters and signals obtained from multiple sensors. The output signals are measured by an acoustic emission (AE) sensor and an accelerometer and are analyzed in the signal frequency domain. By using the wavelet transform of analyzed signals, we determine the correlation between surface quality and signals. Based on this investigation, a surface quality monitoring system can be suggested.

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.

An Experimental Study of the Effect of Cutting Parameters on Micro Milling Process

2012 ◽  
Vol 565 ◽  
pp. 558-563 ◽  
Author(s):  
Bing Wu ◽  
Huai Zhong Li ◽  
Jun Wang ◽  
Xiu Bing Jing
Keyword(s):  
Experimental Study ◽  
Surface Quality ◽  
Significant Influence ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Milling Process ◽  
Micro Milling ◽  
Material Hardness ◽  
Tool Diameter

In micro milling, cutting parameters such as feed per tooth and cutting speed are found to have significant influence on cutting forces and surface quality. To address these issues, an experimental study of micro milling with three types of metal material (steel, brass and aluminium alloy) is conducted. The experiment setup and cutting conditions are described; the experiment results are presented with a discussion of the influence of various cutting parameters such as feed per tooth and tool diameter. These results are used to provide strategies to optimise cutting parameters and achieve better surface quality with the concern of tool diameter and material hardness when micro milling selected materials.

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.

Vibration Analysis Based on AR Trispectrum in Milling Process

2010 ◽  
Vol 97-101 ◽  
pp. 1895-1901
Author(s):  
Yu Yan Jiang ◽  
Yi Jian Huang ◽  
Xiu Cheng Ye
Keyword(s):  
Surface Quality ◽  
Vibration Analysis ◽  
Metal Cutting ◽  
Cutting Parameters ◽  
Milling Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Machined Surface Quality

This paper presents the use of vibration analysis based on autoregressive (AR) trispectrum in milling process to indicate the relationship between machined surface quality of workpiece and spectrum character under a variety of different cutting parameter settings, such as the depth of cut, the feed rate and the spindle speed. The metal cutting experiments were performed on steel A3 material without using any cutting fluid. The experimental results for slices analysis of trispectra indicated that the spectral peaks were abundant as the milling process went smoothly. The roughness value measured reflects the machined surface quality of workpice. According to the changes for spectral peak and roughness value, a conclusion was made that the proposed trispectrum slices method for choosing cutting parameters and monitoring the machined surface quality in milling process was practicable.

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.

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.

The Investigation of a Micro-Component Machined on a Custom-built Miniature Machine Tool

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Syaimak Abdul Shukor
Keyword(s):  
Surface Quality ◽  
Milling Process ◽  
Micro Milling ◽  
Batch Size ◽  
Geometrical Accuracy ◽  
Custom Made ◽  
Micro Parts ◽  
Solid Carbide ◽  
Steel Aisi

Custom-built Miniature Machine Tools (MMTs) are now becoming more popular with the demand for reduced energy consumption and workshop floor when machining small/medium batch size micro-components. This paper investigates the capability of a custom-built 4-axis MMT through machining an “adapted standard‟ of micro-testpiece. The experiments have been carried out in two different materials: Carbon Steel (AISI 1040) and Titanium Alloyed (TiAl6V4) using solid carbide flat end mill cutters with 0.6mm diameter. From here, the surface quality and geometrical accuracy of the machined testpiece are evaluated and analysed. The investigation has shown that acceptable geometrical accuracies and surface quality of the machined micro-parts can be achieved using the in-house developed MMT. These results show that the use of the custom-made MMT does not hinder the micro-milling process to produce a good and satisfactory surface quality (Ra=0.04-0.07μm) and acceptable geometrical accuracy.

Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring

2019 ◽  
Vol 234 (5) ◽  
pp. 871-880 ◽  
Author(s):  
Yinfei Yang ◽  
Jinjin Han ◽  
Xiuqing Hao ◽  
Liang Li ◽  
Ning He
Keyword(s):  
Aspect Ratio ◽  
Tool Wear ◽  
Surface Quality ◽  
High Aspect Ratio ◽  
High Conductivity ◽  
Cutting Fluid ◽  
Micro Milling ◽  
Free Alcohol ◽  
Processing Efficiency ◽  
Machined Surface

High aspect ratio micro-grooves are critical structures in the micro-electromechanical system. However, problems like rapid tool wear, low processing efficiency, and inferior machined quality in micro-milling of high aspect ratio micro-grooves by length–diameter ratio tools are particularly significant. In this work, a combined micro-milling method based on water-free alcohol as the cutting fluid and laser deburring is proposed to investigate the high aspect ratio micro-groove generation of oxygen-free high-conductivity copper TU1. Parametric experiments and high aspect ratio micro-groove experiments were conducted to investigate the surface quality, cutting forces, and tool wear. The water-free alcohol was employed to improve the tool life and machined surface quality. In the case of the oxygen-free high-conductivity copper TU1 material, a satisfactory high aspect ratio micro-groove (groove-width = 0.2 μm and aspect ratio = 2.5) with a nanoscale surface roughness ( Ra = 68 nm) was obtained under the preferred machining conditions. Furthermore, the deburring process of the high aspect ratio micro-groove by the laser technology was conducted to achieve ideal machined quality of the top surfaces.

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