Experimental study of micro-milling mechanism and surface quality of a nickel-based single crystal superalloy

Gao, Qi; Gong, Yadong; Zhou, Yunguang; Wen, Xuelong

doi:10.1007/s12206-016-1218-y

Cited by 23 publications

(13 citation statements)

References 16 publications

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“…Inconel 718: [41], [76], [85], [158], [159], [160], [196], [200], [201], [202] Inconel 182: [203] GH4169: [204] Nimonic 75: [79] DD98: [205] Titanium and its alloy Ti-6Al-4V: [5], [32], [35], [70], [82], [86], [94], [108], [113], [124], [126], [129], [134], [150], [151], [152], [155], [156], [196], [206], [207], [208], [209], [210], [211], [212], [213], [214], [215], [216], [217] Grade 2: [40], [193], [218], [219], [220] CP tit...…”

Section: Superalloysmentioning

confidence: 99%

“…can be estimated without numerous experimental work, which is often time and cost consuming. The micromilling process was modelled and simulated by the researchers using (i) analytical models [78,148,239], (ii) numerical models [117,191,249], (iii) regression analysis [42,171] or (iv) response surface methodology [200,201,205]. Table 4 summarises the key scientific studies from the past five years in the topic of modelling of the micro-milling process.…”

Section: Micro-milling Modellingmentioning

confidence: 99%

“…It has been found that by increasing the feed and depth of cut, the presence of continuous chip removal becomes much more apparent while the forces also increase. Zhou et al [123] [168] Finite element modelling h min , tool run-out Surface profile, surface roughness Peng et al [191] Finite element modelling Cutting speed, feed rate Temperature and cutting deformation Wojciechowski et al [47] Combined numerical-analytical approach [200] Response surface methodology Spindle speed, feed per tooth, depth of cut Vickers hardness Lu et al [201] Response surface methodology Spindle speed, feed per tooth, depth of cut Surface roughness Gao et al [205] Response surface methodology Spindle speed, feed per tooth, depth of cut Surface roughness Abolfazl Zahedi et al [278] Smoother particle hydrodynamics combined with continuum finite element analysis…”

Section: Micro-milling Modellingmentioning

confidence: 99%

See 2 more Smart Citations

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

133

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Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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Section: Superalloysmentioning

confidence: 99%

Section: Micro-milling Modellingmentioning

confidence: 99%

Section: Micro-milling Modellingmentioning

confidence: 99%

See 1 more Smart Citation

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

133

View full text Add to dashboard Cite

show abstract

“…Additionally, Aurich et al showed that the tilt angle of the main spindle significantly changes material removal on the microscale and influences burr formation as well as surface topography [ 7 ]. Gao et al surveyed different micro-milling parameters of nickel-based single crystal superalloy [ 8 ]. He discovered that feed rate, spindle speed, and milling depth have the most influence on surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Effect of End Mill-Geometry on Roughness and Surface Strain-Hardening of Aluminum Alloy AA6082

et al. 2020

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Micro-milling is a promising technology for micro-manufacturing of high-tech components. A deep understanding of the micro-milling process is necessary since a simple downscaling from conventional milling is impossible. In this study, the effect of the mill geometry and feed per tooth on roughness and indentation hardness of micro-machined AA6082 surfaces is analyzed. A solid carbide (SC) single-tooth end-mill (cutting edge radius 670 nm) is compared to a monocrystalline diamond (MD) end-mill (cutting edge radius 17 nm). Feed per tooth was varied by 3 m , 8 m and 14 m . The machined surface roughness was analyzed microscopically, while surface strain-hardening was determined using an indentation procedure with multiple partial unload cycles. No significant feed per tooth influence on surface roughness or mechanical properties was observed within the chosen range. Tools’ cutting edge roughness is demonstrated to be the main factor influencing the surface roughness. The SC-tool machined surfaces had an average R q = 119 nm, while the MD-tool machined surfaces reached R q = 26 nm. Surface strain-hardening is influenced mainly by the cutting edge radius (size-effect). For surfaces produced with the SC-tool, depth of the strain-hardened zone is higher than 200 nm and the hardness increases up to 160% compared to bulk. MD-tool produced a thinner strain-hardened zone of max. 60 nm while the hardness increased up to 125% at the surface. These findings are especially important for the high-precision manufacturing of measurement technology modules for the terahertz range.

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“…Most of these studies have focused on slot and channel operations [12][13][14][15]. Nevertheless, very few researches have been dedicated to pocket milling, profile milling, and the machining of different geometries with micro cutting tools.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Tool Path Strategy and Cooling Condition Effects on the Cutting Force and Surface Quality in Micromilling Operations

Köklü

Basmacı

2017

Metals

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Abstract:Compared to milling on a macro scale, the micromilling process has several cumbersome points that need to be addressed. Rapid tool wear and fracture, severe burr formation, and poor surface quality are the major problems encountered in the micromilling process. This study aimed to reveal the effect of cutting path strategies on the cutting force and surface quality in the micromilling of a pocket. The hatch zigzag tool path strategy and the contour climb tool path strategy under different cooling conditions (e.g., dry, air blow, and flood coolant) at fixed cutting parameters. The micromilling tests revealed that better results were obtained with the use of the contour tool path strategy in terms of cutting forces (by up to~43% compared to the dry condition) and surface quality (by up to~44% compared to the air blow condition) when compared to the hatch tool path strategy. In addition, the flood coolant reduces the cutting temperature and eliminates chips to significantly enhance the quality of the micro milled surface.

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Experimental study of micro-milling mechanism and surface quality of a nickel-based single crystal superalloy

Cited by 23 publications

References 16 publications

A review on micro-milling: recent advances and future trends

A review on micro-milling: recent advances and future trends

Investigation of the Effect of End Mill-Geometry on Roughness and Surface Strain-Hardening of Aluminum Alloy AA6082

Evaluation of Tool Path Strategy and Cooling Condition Effects on the Cutting Force and Surface Quality in Micromilling Operations

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