Chip formation in microscale milling and correlation with acoustic emission signal

Mian, A J; Driver, Nicholas; Mativenga, Paul

doi:10.1007/s00170-011-3185-x

Cited by 37 publications

(15 citation statements)

References 40 publications

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“…20 It has been reported earlier that surface finish is related to the formation of shear bands in chip and cutting below the minimum chip thickness causes rubbing between the tool and the workpiece, affecting surface quality. 21 Based on the rake angle of cutting tools, no chip was reported to have formed at negative rake angles of 85°while they were shown to have formed at 75°nega-tive rake angle. 22 Minimum chip thickness can also been defined as a measure of extreme accuracy attainable for a given set of parameters.…”

Section: Property Materialsmentioning

confidence: 99%

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Statistical analysis of process parameters in micromachining of Ti-6Al-4V alloy

Jaffery

Khan

Ali

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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The demand for miniaturized components is on the rise, especially from the biomedical and aerospace industry. As a result, there is a strong research potential towards the micro-manufacturing of biomedical and aerospace components. Titanium-based alloys are known for their biocompatibility and high strength-to-weight ratio, making them most suitable for such applications. In this research, flank wear progression, surface roughness and side burrs, the basic performance parameters of a typical micromachining operation, are presented and analysed through analysis of variance in order to determine the key process parameters. It was found that micromachining can be classified into two categories: micromachining with undeformed chip thickness below the tool edge radius and micromachining keeping the undeformed chip thickness above the tool edge radius. The results showed that when machining with undeformed chip thickness above edge radius, the feedrate remains the most significant parameter affecting tool wear (41% contribution ratio), surface roughness (83%) and burr width (80%). This result places this type of machining closer to macro-machining where feed contribution was found to be 69%, 92% and 75% as against micromachining below edge radius, where contributions stood at 17%, 53% and 52% on tool wear, surface roughness and burr width, respectively. The results underscored the importance of considering the tool edge radius in micromachining.

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Section: Property Materialsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Statistical analysis of process parameters in micromachining of Ti-6Al-4V alloy

Jaffery

Khan

Ali

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…Recently, small and low-cost sensors for machining process monitoring have been developed to overcome the above technological and industrial limitations including piezo electric sensors fibre Bragg grating sensor and acoustic wave sensor [ 16 , 17 , 18 , 19 ]. These achievements had mainly focused on the compact integration with existing equipment or machine to minimise the effect on the process or lowering sensor fabrication cost.…”

Section: Introductionmentioning

confidence: 99%

Directly Printed Low-Cost Nanoparticle Sensor for Vibration Measurement during Milling Process

Min

Lee

et al. 2020

Materials

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A real-time, accurate, and reliable process monitoring is a basic and crucial enabler of intelligent manufacturing operation and digital twin applications. In this study, we represent a novel vibration measurement method for workpiece during the milling process using a low-cost nanoparticle vibration sensor. We directly printed the vibration sensor based on silver nanoparticles positioned onto a polyimide substrate using an aerodynamically-focused nanomaterials printing system, which is a direct printing technique for inorganic nanomaterials positioned onto a flexible substrate. Since it does not require any post-process such as chemical etching and heat treatment, a highly sensitive vibration sensor composed of a microscale porous structure was fabricated at a cost of several cents each. Furthermore, accurate and reliable vibration data was obtained by simple and direct attachment to a workpiece. In this study, we discussed the performance of vibration measurement of a fabricated sensor in comparison to a commercial vibration sensor. Using frequency and power spectrum analysis of obtained data, we directly measured the vibration of workpiece during the milling process, according to a process parameter. Lastly, we applied a fabricated sensor for the digital twins of turbine blade manufacturing in which vibration greatly affects the quality of the product to predict the process defects in real-time.

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“…Aamer Jalil Mian conducted micromilling experiment on NiTi alloy and found that feed rate to undeformed minimum chip thickness is the most critical factor in reducing burr root thickness. At high values of chip load, cutting starts earlier as compared to low undeformed chip thickness, as a consequence of this, ploughing effect becomes less pronounced (Mian et al, 2011b). Ravi Lekkala analyzed the burr formation in micro end milling of Aluminum and Steel using experimental and theoretical techniques and reported that either in down milling or up milling, burr height increases with the decrease in number of flutes and cutting tool diameter and burrs formed in the case of stainless steel were larger than aluminum (Lekkala et al, 2011).…”

mentioning

confidence: 99%

Analysis of Burr Formation in Low Speed Micro-milling of Titanium Alloy (Ti-6Al-4V)

et al. 2018

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Abstract. The use of titanium based alloys in aerospace and biomedical applications make them an attractive choice for research in micro-machining. In this research, low speed micro-milling is used to analyze machinability of Ti-6Al-4V alloy as low speed machining setup is not expensive and it can be carried out on conventional machine tools already available at most machining setups. Parameters like feed per tooth, cutting speed and depth of cut are selected as machining variables and their effect on burr formation is analyzed through statistical technique analysis of variance to determine key process variables. Results show that feed per tooth is the most dominant factor in burr formation (81 % contribution ratio). The effect of depth of cut was found to be negligible. It was also observed that micro-milling at optimum process parameters showed minimum burr formation. In terms of burr formation, as compared to high speed machining setup, better results were achieved at low speed machining setup by varying machining parameters.

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Chip formation in microscale milling and correlation with acoustic emission signal

Cited by 37 publications

References 40 publications

Statistical analysis of process parameters in micromachining of Ti-6Al-4V alloy

Statistical analysis of process parameters in micromachining of Ti-6Al-4V alloy

Directly Printed Low-Cost Nanoparticle Sensor for Vibration Measurement during Milling Process

Analysis of Burr Formation in Low Speed Micro-milling of Titanium Alloy (Ti-6Al-4V)

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