Investigation on tooling geometrical effects of micro tools and the associated micro milling performance

Wu, Tao; Cheng, Kai; Rakowski, R.T.

doi:10.1177/0954405412449229

Cited by 22 publications

(9 citation statements)

References 17 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…It details that (i) the increase of tool radius due to tooltip roundness makes the micro-tools blunt, consequently, generating high shear angle in cutting area or high plastic deformation of the workpiece, hence increasing cutting force, and (ii) the tooltip roundness increases the contact area between flank face and workpiece, therefore, accelerating flank wear rate. It generates high cutting temperature [23], especially when micro-cutting inhomogenous nanocomposites using uncoated tools with the high friction coefficient at high cutting speed. Thus, the thermal softening effect seems dominant in this case, causing more chip adhesion on the flank face of the uncoated tool (Fig.…”

Section: Tool Wear Analysismentioning

confidence: 99%

See 1 more Smart Citation

An experimental investigation on tool wear behaviour of uncoated and coated micro-tools in micro-milling of graphene-reinforced polymer nanocomposites

Shakoori

Liu

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Nanomaterials such as graphene have been added to various matrices to enhance mechanical, thermal and electrical properties for various applications requiring intricate designs at the micro-scale. At this scale, mechanical micro-machining is utilised as post-processing to achieve high surface quality and dimensional accuracy while still maintaining high productivity. Therefore, in this study, the machinability of polymer nanocomposites in micro-scale (micro-machinability) is investigated. Graphene (0.3 wt%)-reinforced epoxy nanocomposites were fabricated using traditional solution mixing and moulding. The samples were then subjected to micro-milling at various cutting speeds using three different micro-tools, including uncoated, diamond and diamond-like carbon (DLC) tools. Mechanical and thermal properties of nanocomposite were also used to support the discussions. The result indicates that the DLC-coated tool shows better performance than the other tools for less tool wear, improved surface quality and less cutting forces.

show abstract

Section: Tool Wear Analysismentioning

confidence: 99%

“…Therefore, investigations on the micro-machining behaviours of nanocomposites are necessary. The increases of uncut chip thickness (UCT) [22] associated with cutting edge radius due to tool wear acceleration can result in cutting force rising in micro-machining of metals [23] or nanocomposites [16].…”

Section: Introductionmentioning

confidence: 99%

An experimental investigation on tool wear behaviour of uncoated and coated micro-tools in micro-milling of graphene-reinforced polymer nanocomposites

Shakoori

Liu

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Micro milling operations are performed on an ultraprecision micro milling machine UltraMill and the experiment has the same setup as in the literatures Wu and Cheng 11 and Wu et al 12 A dynamometer MiniDyn 9256C2 together with a digital camera is employed, respectively, for recording the forces and aligning the tool positions.…”

Section: Micro Milling Trialsmentioning

confidence: 99%

Micro milling performance assessment of diamond-like carbon coatings on a micro-end mill

Cheng

2013

Proceedings of the Institution of Mechanical Engineers, Part J:

Self Cite

View full text Add to dashboard Cite

In micro milling, unpredictable tool life and premature tool failures are the major constraints for its industrial applications, and prolongation of the tool life so as to enhance the tooling performance presents great challenges. Appropriate coating techniques potentially offer a feasible and promising solution. In the research presented, diamond-like carbon (DLC) films are deposited on a Ø500µm diameter tungsten carbide (WC) micro end mill by the plasma enhanced chemical vapor deposition (PE-CVD) process. Coating characterization has been undertaken and the DLC coatings are found in good coverage on the tool except for a slight delaminating on the edge corners. Besides, the surface of the amorphous coatings is much smoother than that of WC. In addition, comprehensive cutting performance of the DLC coated tool in dry slot milling of Al 6061-T6 has been compared with those of uncoated tools in both dry and wet conditions. It is observed that the use of DLC coatings can reduce the cutting forces, lessen the tool wear, improve the surface roughness and minimize the microburr formation as compared to the corresponding performance of an uncoated tool in dry cutting. However, the performance improvement is still unreachable to those resulting from the cutting fluid influence.

show abstract

“…In this case, since the chip thickness is smaller than the minimum chip thickness, a complete cutting operation does not occur. 1 This is called ploughing or plowing. The plowing continues until the chip thickness is equal to/greater than the minimum chip thickness.…”

Section: Introductionmentioning

confidence: 99%

An experimental analysis of minimum chip thickness in micro-milling of two different titanium alloys

Aslantaş

Alatrushi

Bedir

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Micro-milling is a micro-mechanical cutting method used to obtain complex and three-dimensional micro geometries. Micro-cutting tools are used in the manufacturing of micro-components and the type of workpiece is also important for good surface quality and minimum burr. In this study, micro machinability of Ti6Al4V alloy which is used most frequently in micro-component production is compared with Ti5553 alloy. Micro-milling of Ti5553 alloy and comparison of the minimum chip thickness with Ti6Al4V were performed for the first time in this study. Using different cutting parameters, the variation of surface roughness, burr width, and cutting forces were investigated. The cutting tests were carried out on a specially designed and high-precision micro-milling test system using a TiCN-coated two-flute end mill of 0.6 mm diameter. According to the results, minimum chip thickness is approximately 0.3 times the edge radius of the cutting tool and does not vary with the alloy type. At feed rates smaller than the minimum chip thickness, both the cutting forces increase and the surface quality decreases. For both alloys, reduced feed rate and increased depth of cut lead to increased burr width. The burr widths in Ti6Al4V alloy are higher. At the end of the study, the limits of the cutting parameters where plowing occurred for the both alloys are clearly determined. In addition, the limits of the cutting parameter causing plowing have been confirmed by cutting forces, surface roughness, and burr formation.

show abstract

Investigation on tooling geometrical effects of micro tools and the associated micro milling performance

Cited by 22 publications

References 17 publications

An experimental investigation on tool wear behaviour of uncoated and coated micro-tools in micro-milling of graphene-reinforced polymer nanocomposites

An experimental investigation on tool wear behaviour of uncoated and coated micro-tools in micro-milling of graphene-reinforced polymer nanocomposites

Micro milling performance assessment of diamond-like carbon coatings on a micro-end mill

An experimental analysis of minimum chip thickness in micro-milling of two different titanium alloys

Contact Info

Product

Resources

About