Investigation on surface quality and burr generation of high aspect ratio (HAR) micro-milled grooves

Han, Jinjin; Hao, Xiaohong; Li, Liang; Liu, Linghui; Chen, Ni; Zhao, Guolong; He, Ning

doi:10.1016/j.jmapro.2020.01.041

Cited by 34 publications

(7 citation statements)

References 34 publications

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“…39 It was clearly found that the burr size from up milling side was generally much smaller than the one from down milling side caused by cut in or cut out, which was in line with previous findings. 40 On the up milling side, the cutter teeth cut in the workpiece and a small amount of Poisson burrs were produced, which were formed by the material's bulge to the sides when they were compressed until permanent plastic deformation occurred. 39 Consequently, the analysis of burr formation in this work only concentrated upon that from down milling side.…”

Section: Burr Formationmentioning

confidence: 99%

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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High-efficient machining of SiC particles reinforced composites is always challenging mainly due to their poor surface integrity. In this study, a two-phase finite element model including the Al alloy matrix with Johnson-Cook model and SiC particle with elastic-brittle failure model were developed. The main purpose is to comprehensively investigate particle removal mechanisms and surface integrity following simulation and experimental studies on milling SiCp/Al composites. Specifically, the distributions of residual stress along the depth direction were predicted using finite element model. Results indicated that compressive residual stress mainly appeared on the machined surface, while tensile residual stress distributed at deeper depth down to 0.02 mm. Besides, different relative positions between tool and particle induced specific particle removal modes, which eventually led to various surface defects. Higher level of cutting speed (180 m/min) and feed rate (0.09 mm/tooth) aggravated surface defects and increased the thickness of broken-SiC layer in subsurface. The simulated machined surface defects and surface residual stress correlated well with the experimental observation, and the maximum error value of cutting force was less than 15%. The proposed finite element model was efficient to predict cutting force and distribution of residual stress along the depth direction.

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Section: Burr Formationmentioning

confidence: 99%

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…However, large burrs will result from the plowing action if a depth of cut higher than 0.2 mm is used. Han et al, [17] analyzed the effect of cutting fluids and the wear of micro-milling tools on surface quality and microburr generation. The findings indicated that the formation of burrs and the quality of the surface were highly dependent on both the depth of the groove and the wear of the tool.…”

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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“…Many materials such as heat treated steel, plastic, casting, composite, alloy with different properties and shapes can be processed with very high productivity and accuracy by the end milling method containing flat and/or ball end mills [1]. It is widely used in aerospace, defense, military sectors due to it can achieve high surface quality in casting materials at low cost, as well as precision processing of many materials [2][3]. The parts used in the aviation industry and the molds used in the production of these parts must be processed precisely and with a good surface quality [4].…”

Section: Introductionmentioning

confidence: 99%

The Effects of Cutting Parameters Used in Milling X153CrMoV12 Cold Work Tool Steel by End Mills on Surface Roughness and Hardness of The Workpiece

Ceritbinmez¹,

Kanca

2022

Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım Ve Teknoloji

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The goal of this project is to investigate the effect of the spindle speed and feed rate used in milling X153CrMoV12 cold work steel by X5070 blue coated solid carbide end mill on surface roughness and hardness of the workpiece. For this purpose, 0.2 mm material was removed in one pass without using refrigerant with the machining parameters of 2000, 2500, 2800, 3000 rpm spindle speed and 160, 180, 200, 240 mm/min feed rate. As a result of the tests, the topographic structure, surface roughness, surface hardness and microhardness of the machined surfaces were determined by Leica DMS300, Mitutoyo SJ 210, HRS-150 digital rockwell hardness tester and microhardness tester Future-Tech FM-700, respectively. As the feed rate increased at a constant 2800 rpm spindle speed, the surface roughness (SR) increased as the amount of metal removed per unit time increased. As the spindle speed increased at a constant feed rate of 180 mm/min, the amount of chips for the next cutting decreased, as the cutting blade removed more chips with each turn, and therefore the surface roughness decreased. The effects of spindle speed and feed rate machining parameters on the surface hardness were not much, and the hardness value before and after the process was measured between 60-62 HRC. However, it was determined that the microhardness value decreased due to the use of heathardened steel as well as the heat generated by the milling parameters in the regions 50-350 µm deep from the machined surface.

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Investigation on surface quality and burr generation of high aspect ratio (HAR) micro-milled grooves

Cited by 34 publications

References 34 publications

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

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

The Effects of Cutting Parameters Used in Milling X153CrMoV12 Cold Work Tool Steel by End Mills on Surface Roughness and Hardness of The Workpiece

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