FE modeling of burr size in high- speed micro-milling of Ti6Al4V

Yadav, Amrendra K.; Kumar, Mohan; Bajpai, Vivek K.; Singh, Nirmal; Singh, Ramesh

doi:10.1016/j.precisioneng.2017.02.017

Cited by 66 publications

(31 citation statements)

References 24 publications

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“…The uncut material is pushed out of the top of the slot, which is in the direction with the lowest resistance, thereby generating a large irregular tearing burr on the down milling side. Therefore, for ductile material micro milling, the surface quality on the up milling side is better than that of the down milling side as reported in [6,7] and confirmed in this research. Based on the top burr formation mechanism, a burr control strategy with the aid of vibration is proposed.…”

Section: Kinematics Analysissupporting

confidence: 84%

“…The Johnson-Cook (JC) material constitutive and damage models are used to model material plasticity and damage respectively. Details of the JC model parameters of the material can be found in [11]. The coefficient of friction between tool and workpiece is set at 0.6.…”

Section: Finite Element Simulationmentioning

confidence: 99%

“…They pointed out that in the up milling process of a slot, the top burr height is evidently reduced, but it tends to increase with cutting speed. By conducting finite element simulation, Yadav et al [7] investigated the micro milling of Ti6Al4V and found that burrs are usually formed on the up milling side at the exit of the micro milling tool. Saptaji et al [8] studied the effect of side edge angle and rake angle on top burrs in micro milling and found that as the taper angle increases, the top burrs were reduced significantly.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Burr reduction mechanism in vibration-assisted micro milling

Chen

Teng

Zheng

et al. 2018

Manufacturing Letters

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This paper investigates the effect of vibration applied in feed direction on the burr generation mechanism in vibration-assisted micro milling. Kinematic analysis and finite element simulation are conducted for micro slot milling. Due to the vibration assistance in the feed direction, up milling and down milling takes place periodically on both of the cutting-in and cutting-out sides. This results in a reduction of burr formation. The results from both simulation and experiment confirm that the size of the top burrs in the down milling side of the slot are reduced significantly due to vibration assistance compared with conventional micro milling.

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Section: Kinematics Analysissupporting

confidence: 84%

Section: Finite Element Simulationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Burr reduction mechanism in vibration-assisted micro milling

Chen

Teng

Zheng

et al. 2018

Manufacturing Letters

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“…Table 2. Mechanical properties and materials constant in the Johnson-Cook (J-C) model for titanium alloy [24].…”

Section: Finite Element Simulationsmentioning

confidence: 99%

Investigation on the Tool Wear Suppression Mechanism in Non-Resonant Vibration-Assisted Micro Milling

2020

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Excessive tool wear during hard and brittle material processing severely influences cutting performance. As one of the advanced machining technologies, vibration-assisted micro milling adds high-frequency small amplitude vibration on a micro milling tool or workpiece to improve cutting performance, especially for hard and brittle materials. In this paper, the tool wear suppression mechanism in non-resonant vibration-assisted micro milling is studied by using both finite element simulation and experiment methods. A finite element model of vibration-assisted micro milling using ABAQUS is developed based on the Johnson cook material and damage models. The tool-workpiece separation conditions are studied by considering the tool tip trajectories. The machining experiments are carried out on Ti-6Al-4V with a coated micro milling tool (fine-grain tungsten carbide substrate with ZrO2-BaCrO4 (ZB) coating) under different vibration frequencies (high, medium, and low) and cutting states (tool-workpiece separation or non-separation). The results show that tool wear can be reduced effectively in vibration-assisted micro milling due to different wear suppression mechanisms. The relationship between tool wear and cutting performance is studied, and the results indicate that besides tool wear reduction, better surface finish, lower burrs, and smaller chips can also be obtained as vibration assistance is added.

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“…Instead of measuring techniques, research has been focused on burr reduction for micro-milling, through experimentation [9,12,32,35] or simulation [36][37][38] by varying the process parameters or deburring after machining. The formation of burrs in the macro-milling process has been studied extensively through experimental and predictive analytical modeling, but in the micro-scale, very little work has been reported in the literature.…”

Section: Burr Formationmentioning

confidence: 99%

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Giraldo¹,

Serje²,

Bolívar³

et al. 2017

DYNA

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Micro-machining of different polymer based components often require high precision and excellent surface quality at high production rates with low costs. Micro-milling is a cost-efficient micro-machining process capable of generating complex shapes in a wide range of materials. Challenges based on size effect, burr formation and adequate chip removal must be faced and are addressed in this research. Material removal mechanisms, as well as its impact on burr formation and control are reviewed, followed by a case study through the application of gaseous cooling based on vortex tubes. Different vortex generator configurations were tested, proving to be fast response an economically-friendly alternative for burr reduction while micro-milling biopolymers. Configurations, as mentioned above, were used for biopolymer micro-milling towards burr measurement after each test; achieving as a result, a burr reduction while cooling temperature decreases.Keywords: Micro-milling; Burr; Polymer machining; Vortex cooling.Formación de rebabas y su control para el micro-fresado de polímeros: Un caso de estudio con refrigeración por tubo vortex Resumen El micro-maquinado de diferentes componentes basados en polímeros a menudo requiere de gran precisión y un excelente acabado superficial a unas tasas elevadas de producción con un bajo costo. El micro-fresado es un proceso costo-efectivo de micro-maquinado capaz de generar formas complejas en una amplia variedad de materiales. Retos basados en el efecto tamaño, formación de rebabas y una adecuada remoción de la viruta deben ser enfrentados y son tratados en la presente investigación. Los mecanismos de remoción de material, al igual que su impacto en la formación de rebabas y su control, son revisados, acompañados de un caso de estudio a través de la aplicación de refrigeración gaseosa basada en tubos vortex. Diferentes configuraciones de generadores de vortex son probados, demostrando ser una alternativa de respuesta rápida, económica y amigable para la reducción de rebabas mientras se micro-fresan biopolímeros. Dichas configuraciones se utilizaron en el micro-mecanizado de un polímero bio-compatible, midiendo el tamaño de rebaba que se genera en cada prueba, dando como resultado la disminución de estas a media que baja la temperatura de refrigeración.Palabras clave: Micro-fresado; Rebaba; Maquinado de polímeros; Refrigeración con tubo vortex.

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FE modeling of burr size in high- speed micro-milling of Ti6Al4V

Cited by 66 publications

References 24 publications

Burr reduction mechanism in vibration-assisted micro milling

Burr reduction mechanism in vibration-assisted micro milling

Investigation on the Tool Wear Suppression Mechanism in Non-Resonant Vibration-Assisted Micro Milling

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

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