Experimental investigation of porous metal materials in high-speed micro-milling process

Liu, Zhiqiang; Su, Yu; An, Qinglong

doi:10.1177/0954405417699011

Cited by 8 publications

(4 citation statements)

References 22 publications

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“…The wear mechanism of porous titanium material is abrasive wear and slight oxidation wear at room temperature. 7 Liu et al 8 , also studied the cutting temperature in the micro-milling of porous stainless steel, and poined out that accelerating the cutting speed or increasing the axial cut depth can increase the micro-milling temperature. Heidari and Yan 9 attempted ultraprecision surface flattening of porous silicon by diamond turning and studied the fundamental material removal mechanism.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on electrical discharge machining of porous and pure 316L stainless steel

Duan,

Hu,

Kun

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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Porous metal materials are widely used in heat-absorbing, biomedical parts and other fields because of their excellent mechanical properties and biocompatibility. Further applications of porous metal materials are inseparable from secondary precision machining. However, traditional cutting methods tend to compromise the original porosity of the material surface. Electrical discharge machining (EDM) is a type of non-conventional machining method which is more preferable to overcome these defects. In the present study, the main target is to investigate the effect of four input electrical machining parameters (current, frequency, efficiency and gap voltage) on the five output responses (material removal rate (MRR), electrode wear, surface roughness (SR), noise and time consumption value of environmental particulate matter (PM2.5)) when electrical discharge machining porous 316L stainless steel and compared with that of pure 316L stainless steel. The Taguchi method was employed to determine the relationship between electrical discharge machining parameters and output responses. The analysis of variance (ANOVA) was used to evaluate the effect of input parameters on output responses. The effects of electrical machining parameters on above responses were analyzed by main effects, and the order of influence was obtained, respectively. Finally, the surface morphology was observed by scanning electron microscope (SEM), and the effect of electrical machining parameters on the characteristics and formation of machined surface of porous stainless steel was mainly analyzed.

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Section: Introductionmentioning

confidence: 99%

Experimental study on electrical discharge machining of porous and pure 316L stainless steel

Duan,

Hu,

Kun

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…The porosity not only causes a low heat transfer rate, but also leads to discontinuous cutting, thus imposing a cyclic load on the tool tip. 6,8 In order to control the influence of the surface porosity on the machinability, the mechanism of cutting the porous materials should be analyzed. This has not been given sufficient consideration except for very limited cases, mainly on micro scales.…”

Section: Introductionmentioning

confidence: 99%

“…Porous stainless steel is widely used for biomedical materials due to its high strength-to-weight ratio and excellent corrosion resistance. 6 The austenitic stainless steels are often used in medical applications such as orthopedic implants due to their properties such as corrosion resistance, high fatigue and high fracture resistance. However, the main problem with orthopedic metal implants is the Young’s modulus mismatch between non-porous metal and bone.…”

Section: Introductionmentioning

confidence: 99%

An investigation on the material removal mechanism, surface porosity, and surface integrity in ultrasonic vibration assisted turning of porous stainless steel 316L

Ghorbani

Nategh

Karafi

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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The machining of porous materials is commonly accompanied with high and irregular cutting forces, high cutting temperature, poor surface integrity, and severe tool wear. The porous materials are considered difficult to be machined. Porosity reduces the rate of heat transfer; moreover, it impairs the continuous cutting and therefore leads to cyclic loads. The main objective of the present study is to investigate the influence of superimposing ultrasonic vibration to the cutting motion of the cutting tool on the surface integrity of the porous materials. For this purpose, the mechanism of chip removal in vibration assisted machining of porous materials was analyzed and porous stainless steel 316L specimens were machined by ultrasonic vibration assisted turning. It was illustrated by the porosimetry of the machined surfaces that the surfaces machined by conventional turning had higher rate of surface porosity compared with ultrasonic vibration assisted turning. In the latter process, the SEM images of the machined surfaces manifested the existence of a kind of rubbing mechanism and material overlaps, which was attributable to the friction existing between the cutting tool with micro scale reciprocating motion and the surface of the workpiece. The overall impact of imposing ultrasonic vibration to the cutting tool motion in the cutting direction was the achievement of a trade-off between preserving the porosity and improvement of the surface quality. This effect was bolstered by increasing the vibration amplitude.

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“…Emel Kuram and Babur Ozcelik 20 determined the regression models using Taguchi experimental design method with two kinds of aerospace materials (titanium and nickel-based superalloy). Similarly, Zhiqiang Liu et al 21 established a preliminary relationship of cutting parameters with micro-milling force and milling temperature to discuss the effects of cutting parameters on the micro-milling force and temperature. Rinku K. Mittal et al 22 found that high-speed micro-milling of Ti6Al4V generates high temperature in cutting zone and leads to a variation in cutting force.…”

Section: Introductionmentioning

confidence: 99%

Coupled thermal and mechanical analyses of micro-milling Inconel 718

Lü

Wang

Zhang

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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Micro-milling forces, cutting temperature, and thermal–mechanical coupling are the key research topics about the mechanism of micro-milling nickel-based superalloy Inconel 718. Most current analyses of thermal–mechanical coupling in micro-milling are based on finite element or experimental methods. The simulation is not conducive to revealing the micro-milling mechanism, while the results of experiments are only valid for certain machine tool and workpiece material. Few analytical coupling models of cutting force and cutting temperature during micro-milling process have been proposed. Therefore, the authors studied coupled thermal–mechanical analyses of micro-milling Inconel 718 and presented a revised three-dimensional analytical model of micro-milling forces, which considers the effects of the cutting temperature and the ploughing force caused by the arc of cutting edge during shear-dominant cutting process. Then, an analytical cutting temperature model based on Fourier’s law is presented by regarding the contact area as a moving finite-length heat source. Coupling calculation between micro-milling force model and temperature model through an iterative process is conducted. The novelty is including cutting temperature into micro-milling force model, which simulates the interaction between cutting force and cutting temperature during micro-milling process. The established model predicts both micro-milling force and temperature. Finally, experiments are conducted to verify the accuracy of the proposed analytical method. Based on the coupled thermal–mechanical analyses and experimental results, the authors reveal the effects of cutting parameters on micro-milling forces and temperature.

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Experimental investigation of porous metal materials in high-speed micro-milling process

Cited by 8 publications

References 22 publications

Experimental study on electrical discharge machining of porous and pure 316L stainless steel

Experimental study on electrical discharge machining of porous and pure 316L stainless steel

An investigation on the material removal mechanism, surface porosity, and surface integrity in ultrasonic vibration assisted turning of porous stainless steel 316L

Coupled thermal and mechanical analyses of micro-milling Inconel 718

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