Effect of Tool Path Complexity on Top Burrs in Micromilling

Khan, Khalid; Varghese, Alwin; Dixit, Pradeep; Joshi, Suhas S.

doi:10.1016/j.promfg.2019.06.188

Cited by 8 publications

(8 citation statements)

References 23 publications

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“…Figure 5 shows SEM images of the top burrs formed while milling a Y-type aluminium microchannel puncher using a higher feed rate, while Figure 6 shows when using a lower feed rate. This aligns with the finding made by Khan et al, [14], indicating that at lower feed rates, the primary mechanism contributing to burr formation is plowing, and the impact of the depth of cut radius is minimal. During this phase, the cutting tool displaces material rather than efficiently removing it.…”

Section: Effect Of Machining Parameters On Top Micro-burrs Formationsupporting

confidence: 91%

“…The dimensions of burrs are found to be dependent on the curvature of the tool path, with top burrs showing an increase in values as the curvature increases due to a larger plowing region. Additionally, it has been observed that burr dimensions in straight slots are greater at lower feed values, while circular tool paths result in more burrs at higher feed values as reported by Khan et al, [14]. Overall, uncoated carbide tools generally produced fewer burrs than coated tools in the micro-milling of polycarbonate, and the combination of lower feed rate and higher depth of cut or vice versa can minimize burr formation.…”

Section: Introductionmentioning

confidence: 63%

“…Plowing is particularly noticeable at lower feed rates, where the cutting forces might not be adequate to lift the material away, causing the tool to push or displace the material. However, at higher feed rates, the effect of the depth of cut radius becomes more pronounced, resulting in larger-sized burrs everywhere as reported by Khan et al, [14]. As stated by Hajiahmadi [16], increasing feed rates leads to an increase in uncut chip thickness, facilitating the movement of the workpiece across the tool rake face at a greater velocity.…”

Section: Effect Of Machining Parameters On Top Micro-burrs Formationmentioning

confidence: 73%

“…From the literature review by several authors [12][13][14][15][16][17][18], many studies have been conducted to explore the effects of machining parameters on various aspects in the micro-milling process. However, there is still room for further research on the effects of machining parameters on micro burr formation and other issues arising from the micro-milling process, such as cutting tool wear, the generation of cracks due to mechanical stress, long processing time, and so on.…”

Section: Introductionmentioning

confidence: 99%

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Effect of Machining Parameters on Micro-Burrs Formation of Aluminium Puncher using High-Speed Machining Process

Mohd Saifuldin Mohd Mokhtar,

Ahmad Razlan Yusoff,

M. Sobron Yamin Lubis

2024

ARAM

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Micro-burrs are small protrusions or imperfections that can form on the surface of a machined part during the machining process, which may lead to reduced product quality, decreased performance, and increased wear and tear. The formation of micro-burrs on the puncher can adversely affect the accuracy and surface finish of replicated microchannel parts in secondary processes like hot embossing. The objective of this study is to investigate the effect of machining parameters on micro-burr formation in the Y-type Al6061-T6 microchannel puncher. The machining parameters include spindle speed, feed rate, and depth of cut in twenty experimental works designed using the Central Composite Design (CCD) approach for machining with uncoated solid carbide end milling tools. Results indicate that the top micro-burr formation in the Y-type Al6061-T6 microchannel puncher is significantly influenced by feed rates compared to spindle speed and depth of cut. The minimum burr width occurs at a feed rate of 30 mm/min, while maximum burr values are observed at 150 mm/min. The best parameter combination identified in this study is a spindle speed of 14000 r/min, a feed rate of 90 mm/min, and a moderate depth of cut of 50 μm. This knowledge can be applied to selecting appropriate cutting parameters when planning microchannel puncher fabrication using a high-speed machining process to achieve precision and minimize burr formation.

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Section: Effect Of Machining Parameters On Top Micro-burrs Formationsupporting

confidence: 91%

Section: Introductionmentioning

confidence: 63%

Section: Effect Of Machining Parameters On Top Micro-burrs Formationmentioning

confidence: 73%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Effect of Machining Parameters on Micro-Burrs Formation of Aluminium Puncher using High-Speed Machining Process

Mohd Saifuldin Mohd Mokhtar,

Ahmad Razlan Yusoff,

M. Sobron Yamin Lubis

2024

ARAM

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“…There have not been previous studies on the relationship between straight cut tool wear tests and evaluation of tool wear with more complex cutting and realistic feed and speed rates: indeed, there is little work on complex tool paths in micromilling in general. 44 The work carried out herein will allow the applicability of these studies to industrial applications for the first time, vastly enhancing the value of both existing and future studies, and resulting in:…”

Section: Purpose Of Workmentioning

confidence: 98%

Applying experimental micro-tool wear measurement techniques to industrial environments

Alhadeff

Marshall

Curtis

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Productivity in micro-milling is hindered by premature fracture of tools and difficulty predicting wear. This work builds upon previous investigations into tool wear mechanisms and coatings for micro-mills.The technology readiness level of this work exceeds previous studies by investigating the micro-mills for practical applications and comparing this data. 0.5 mm micro end mills are tested with different coatings on CuZn38, and wear curves produced both in the case of simple straight slot testing and milling of complex parts representing industrial applications. The results show that curves produced using straight slots can be used to predict the behaviour of tools used to machine industrial parts. Due to interrupted cutting, tools used in straight slot tests reach the end of steady state wear after approximately 12 s of cutting as compared with 170 s in continuous milling. Typical cutting forces seen for the tools are in the order of 2–4 N. Catastrophic failure is seen towards the end of tool life for a TiAlN tool with a cutting force of over 30 N seen. For the first time a comparison has been made between fundamental tool wear studies and tool wear observed when producing test pieces representative to micro-industrial parts. This presents a novel perspective on tool wear and facilitates the integrating of existing micro-milling research into industry

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