Experiments and finite element simulations on micro-milling of Ti–6Al–4V alloy with uncoated and cBN coated micro-tools

Özel, Tuğrul; Thepsonthi, Thanongsak; Ulutan, Durul; Kaftanoğlu, Bilgin

doi:10.1016/j.cirp.2011.03.087

Cited by 132 publications

(48 citation statements)

References 9 publications

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“…Increasing cutting speed from 51 m/min to 198 m/min improves surface finish from 0.6 µm R z to 0.37µm R z . Similar conclusion was made in another study [11]. Surface finish of Ti-6Al-4V also improves with increasing milling speed, and the effect of speed is more significant than feed.…”

Section: A Introductionsupporting

confidence: 75%

Surface Finish of Ball-End Milled Microchannels

Berestovskyi

Hung

Lomeli

2014

Journal of Micro and Nano-Manufacturing

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This study develops micromanufacturing techniques to fabricate extremely smooth surface finish, high aspect ratio, and complex microchannel patterns. Computer controlled micromilling on a high speed machine system with minimum quantity lubrication is used to remove most materials and define a channel pattern. Assessment of microchannel is performed with optical microscopy, scanning electron microscopy, atomic force microscopy, and white light interferometry. Meso-scale milling confirms the validity of theoretical surface finish of ball-end milling, but surface finish in micro-scale milling is measured to be few orders of magnitude higher. Build-up-edge is reduced with optimally coated tool and milling in minimum quantity lubrication. The surfaces of milled microchannels are then further enhanced by subsequent electrochemical polishing process. When applying to 304, 316L stainless steel alloys and NiTi alloy, this hybrid technique can repeatedly produce microchannels with average surface finish in the range of 100-300 nm.

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Section: A Introductionsupporting

confidence: 75%

Surface Finish of Ball-End Milled Microchannels

Berestovskyi

Hung

Lomeli

2014

Journal of Micro and Nano-Manufacturing

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“…Micro-milling, an emerging micro-manufacturing process, has been successfully applied in fabrication of 3D complex shape micro-components with excellent dimensional accuracy and surface finish over various engineering materials, including metals such as aluminium [4][5][6], copper [7][8][9], titanium alloys [10,11], steels [12,13], graphite [14], tungsten carbides [15], polymers [16,17] and composites [18]. Recently, it has been applied in machining brittle materials and crystals [19][20][21][22][23] with success.…”

Section: Introductionmentioning

confidence: 99%

Surface and subsurface characterisation in micro-milling of monocrystalline silicon

Huo

Lin

Choong

et al. 2015

Int J Adv Manuf Technol

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This paper presents an experimental investigation on surface and subsurface characterisation of micro-machined single-crystal silicon with (100) orientation. Full immersion slot milling was conducted using solid cubic boron nitride (CBN) and diamond-coated fine grain tungsten carbide micro-end mills with a uniform tool diameter of 0.5 mm. The micro-machining experiments were carried out on an ultra-precision micro-machining centre. Formal design of experiments (DoE) techniques were applied to design and analysis of the machining process. Surface roughness, edge chipping formation and subsurface residual stress under varying machining conditions were characterised using white light interferometry, SEM and Raman microspectroscopy. Tens of nanometre-level surface roughness can be achieved under the certain machining conditions, and influences of variation of cutting parameters including cutting speeds, feedrate and axial depth of cut on surface roughness were analysed using analysis of variance (ANOVA) method. Raman microspectroscopy studies show that compressive subsurface residual stress and amorphous phase transformation were observed on most of the micro-machined subsurface, which provides evidence of ductile mode cutting. Surface and subsurface characterisation studies show that the primary material removal mode is ductile or partial ductile using lower feedrate for both tools, and diamond-coated tools can produce better surface quality. Silicon brain implants were fabricated with good dimensional accuracy and edge quality using the optimised machining conditions, which demonstrated that micro-milling is an effective process for fabrication of silicon components at a few tens to a few hundreds of micron scale.

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“…Unfortunately, these machining methods are not able to be used for micro end milling with a miniature tool except cryogenic machining [9] and laser assisted micro end milling [10]. Numerical analysis of machining of this alloy [11], e.g., finite element modeling of end milling of the alloy [12] could be applied to the optimization of the cutting conditions for micro ball end milling with a miniature tool.…”

Section: Introductionmentioning

confidence: 99%

Micro Ball End Milling of Titanium Alloy Using a Tool with a Microstructured Rake Face

Obikawa

Kani

2012

JAMDSM

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Many parts and structures for aerospace engineering, marine engineering, bioengineering, etc. are made of titanium alloy because of its excellent physical, chemical, biological and mechanical properties. These days, bio and medical technologies have developed, so more precise and smaller parts of this alloy are required to be machined. However, end milling of this alloy is not easy though many different types of coated end mills have been developed. In this paper, a micro ball end mill with a microstructured rake face was fabricated using focused iron beam irradiation. Then, the effects of different microstructured rake faces on cutting forces of titanium alloy Ti-6Al-4V were experimentally investigated for better machining conditions of this alloy. As a result, it was found that some particular types of microstructured rake faces reduced the cutting forces effectively.

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Experiments and finite element simulations on micro-milling of Ti–6Al–4V alloy with uncoated and cBN coated micro-tools

Cited by 132 publications

References 9 publications

Surface Finish of Ball-End Milled Microchannels

Surface Finish of Ball-End Milled Microchannels

Surface and subsurface characterisation in micro-milling of monocrystalline silicon

Micro Ball End Milling of Titanium Alloy Using a Tool with a Microstructured Rake Face

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