Investigation, modeling, and optimization of surface roughness in micro-milling of graphite electrodes

Mijušković, Goran; Cica, Djordje

doi:10.1007/s00170-021-07762-4

Cited by 8 publications

(3 citation statements)

References 46 publications

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“…Raman and Wadke [4], reported that micromilling can produce intricate three-dimensional microfeatures with exceptional dimensional accuracy. Additionally, a study by Mijuškovi´c and Cica [5], recorded its efficiency in various materials using sub-millimeter micro-mills with diverse coatings. This is supported by a study from Prakash and Kumar [1], which reported that the advantages of micromilling include producing highly accurate machining results, good surface finish, form accuracy, and the capability to operate at high machining speeds.…”

Section: Introductionmentioning

confidence: 99%

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: Introductionmentioning

confidence: 99%

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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“…Meanwhile, the effect of cutting parameters on the surface quality of graphite has also been investigated. For instance, Schroeter et al [12] investigated the tool condition and surface quality of graphite in down-and up-milling, and found that up-milling prolonged tool life, but downmilling provided better surface quality; Mijušković et al [19] summarized the effect of different machining parameters on surface roughness through micro-milling experiments on graphite; Zhou et al [20] revealed the morphology of graphite chips at different cutting thicknesses using orthogonal cutting experiments, where the chip size and concavity size increased significantly with increasing cutting thickness, and confirmed that tiny chips similar to metal chips were produced when the cutting thickness was small enough.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Modelling and Experimental Validation of the Graphite Cutting Process

Yang,

Wei,

Wang

et al. 2023

Processes

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Graphite is extensively used in the engineering field due to its unique properties, and the study of its cutting mechanism has become particularly important. However, the brittle fracture mechanism of graphite makes it rather easy for cracks with a unique pattern of initiation and growth to develop when processing. Herein, the ABAQUS was selected to establish a finite element model (FEM) of the graphite cutting process. The internal crystal structure of graphite was modelled by a Voronoi structure, and a cohesion unit was globally embedded into the solid unit to simulate crack initiation and growth. In addition, the complete process of chip formation and removal was demonstrated. The analysis of the simulation results showed that the graphite material underwent three periodic cycles of material removal during the cutting process, i.e., large, tiny, and small removal stages. Meanwhile, the simulation results indicated that when ac was large enough, the crack gradually grew inside the graphite and then turned to the upper surface of the graphite. However, when ac was tiny enough, the cracks hardly expanded towards the inside of the graphite but grew upwards for a short period. Then, orthogonal cutting experiments of graphite were conducted, and the FEM was verified based on the experimental chip morphology, machined surface morphology, and current geometric model of the graphite cutting process. The simulation and experimental results were consistent. The hereby-presented FEM was a complement to simulations of the processing of brittle materials.

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“…Among the manufacturing processes, micromilling is one of the most flexible and fastest way to produce complex tridimensional microfeatures with high dimensional accuracy [2]. It can be successfully applied to a wide variety of materials by using micro-scaled mill with diameters in a sub-millimeter range with different coatings [3]. Micromilling is a subtractive process characterized by a contact between the tool cutting edge and the workpiece along a defined path.…”

Section: Introductionmentioning

confidence: 99%

Experimental Optimization of Process Parameters in CuNi18Zn20 Micromachining

et al. 2021

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Ultraprecision micromachining is a technology suitable to fabricate miniaturized and complicated 3-dimensional microstructures and micromechanisms. High geometrical precision and elevated surface finishing are both key requirements in several manufacturing sectors. Electronics, biomedicals, optics and watchmaking industries are some of the fields where micromachining finds applications. In the last years, the integration between product functions, the miniaturization of the features and the increasing of geometrical complexity are trends which are shared by all the cited industrial sectors. These tendencies implicate higher requirements and stricter geometrical and dimensional tolerances in machining. From this perspective, the optimization of the micromachining process parameters assumes a crucial role in order to increase the efficiency and effectiveness of the process. An interesting example is offered by the high-end horology field. The optimization of micro machining is indispensable to achieve excellent surface finishing combined with high precision. The cost-saving objective can be pursued by limiting manual post-finishing and by complying the very strict quality standards directly in micromachining. A micro-machining optimization technique is presented in this a paper. The procedure was applied to manufacturing of main-plates and bridges of a wristwatch movement. Cutting speed, feed rate and depth of cut were varied in an experimental factorial plan in order to investigate their correlation with some fundamental properties of the machined features. The dimensions, the geometry and the surface finishing of holes, pins and pockets were evaluated as results of the micromachining optimization. The identified correlations allow to manufacture a wristwatch movement in conformity with the required technical characteristics and by considering the cost and time constraints.

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Investigation, modeling, and optimization of surface roughness in micro-milling of graphite electrodes

Cited by 8 publications

References 46 publications

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

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

Finite Element Modelling and Experimental Validation of the Graphite Cutting Process

Experimental Optimization of Process Parameters in CuNi18Zn20 Micromachining

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