Modeling and optimization of the flute profile of micro-drill

Zhang, Suyan; Wang, Xibin; Liang, Zhiqiang; Zhou, Tianfeng; Li, Jiao; Pei, Yan

doi:10.1007/s00170-017-0265-6

Cited by 15 publications

(4 citation statements)

References 18 publications

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“…The mathematical model of the drill flute is closely bound with the way it is manufactured, and the flute profile largely depends on the grinding parameters, wheel profile, and position. The flute cross-sectional profile can be obtained by the envelope of the cutting paths [ 19 ], as shown in Figure 2 . The cutting path can be derived as:

where,

, u , and δ are parameters of the wheel profile, and a x and λ are parameters of the wheel position.…”

Section: Mathematical Model Of the Helical Point Micro-drillmentioning

confidence: 99%

“…Based on the grinding process of the helical flank and drill flute presented by Zhang [ 1 , 19 ], the micro-drill is fabricated using a six-axis CNC grinding machine (CNS7d by Makino Seiki Co., Ltd., Kanagawa, Japan), as shown in Figure 7 . The geometry of the grinding wheels and the configuration of the two wheels are shown in Figure 8 .…”

Section: Grinding Experiments Of Helical Point Micro-drills With DImentioning

confidence: 99%

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Research on the Drilling Performance of a Helical Point Micro Drill with Different Geometry Parameters

et al. 2017

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During the micro-drilling process of stainless steel, the wear, fracture, and breakage of the micro-drill easily occur. Micro-drill geometry parameters have significant influence on the drilling performance of the micro-drill. Nowadays, the helical point micro-drill is proposed and its improved drilling performance is validated by some researchers. In this study, to analyze the effect of geometry parameters of the helical point micro-drill on drilling performance, the mathematical models of the helical flank and ground flute are proposed, and the cutting lip shape, rake angle, and uncut chip thickness are calculated using MATLAB software. Then, based on the orthogonal tests, nine kinds of micro-drills with different point angles, web thicknesses, and helix angles are fabricated using a six-axis CNC tool grinder, and micro-drilling experiments on 1Cr18Ni9Ti stainless steel are carried out. The drilling force, the burr height, and the hole wall quality are measured and observed. The results show that the point angle is the main contributing factor for the thrust force and burr height, and the web thickness is the main contributing factor for the micro hole wall quality. The increased point angle offers a larger thrust force, but gives rise to a smaller exit burr. A larger web thickness leads to a larger thrust force and burr height, and results in a poor surface quality. With the helix angle increased, the thrust force and burr height decreases, and the surface quality of micro-hole improves. The geometry parameters with a point angle 70°, a point angle of 40°, and web thickness ratio of 0.2 can used to improve the drilling performance of the helical point micro-drill.

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where,

, u , and δ are parameters of the wheel profile, and a x and λ are parameters of the wheel position.…”

Section: Mathematical Model Of the Helical Point Micro-drillmentioning

confidence: 99%

Section: Grinding Experiments Of Helical Point Micro-drills With DImentioning

confidence: 99%

Research on the Drilling Performance of a Helical Point Micro Drill with Different Geometry Parameters

et al. 2017

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“…Nguyen et al [7] established the contact curve equation by the contact relationship between the grinding wheel and the helical flute surface to calculate the grinding wheel posture. Zhang et al [8] studied a method for modeling and optimization of the micro-drill flute considering the wheel setting angle and the offset distance from the wheel origin to the drill blank origin. Jia et al [9] developed a grinding wheel orientation calculation method that combines the specific process for helical rake flank sharpening with discrete enveloping theory.…”

Section: Introductionmentioning

confidence: 99%

An optimized calculation method of the grinding wheel profile for the helical flute grinding

Jiang¹,

Yang²,

Li³

et al. 2023

Preprint

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Forming grinding process is a crucial method for grinding the helical flute of end mills, and the calculation of the grinding wheel profile is the key to ensure the precision of the helical flute, which is constrained by grinding wheel posture and helical flute profile. However, the current calculation method has not done enough research on the estimation of the feasibility and validity of the grinding wheel profile, which could lead to contradiction between theoretical calculations and practical application. In this paper, an optimized calculation method of the grinding wheel profile for the helical flute forming grinding is proposed, which includes the calculation, analysis and optimization process. Firstly, the parameters of the helical cutting edge and the flute surface are defined, and accurate geometrical models are established. Secondly, the contact condition between the grinding wheel and the flute surface is deduced to calculate the grinding wheel profile by the envelop theory. Thirdly, an optimization method, including profile optimization and grinding wheel wear optimization, is proposed for the calculation of the grinding wheel profile. Finally, the method is verified by simulation machining and the results show that the method can improve the grinding precision and expand the application range of forming grinding technology in helical flute grinding.

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“…Tang et al investigated the influence of chip morphology on chip removal [21]. Zhang et al proposed a way for modeling and optimization of the micro drill, their research results indicated that the micro drill with flute ground by smaller wheel installation angle held straighter cutting lip shape, furthermore, with larger chip evacuation capacity [22].…”

Section: Introductionmentioning

confidence: 99%

Micro hole drilling of high frequency printed circuit board containing hard fillers

Shi¹,

Xian-wen²,

Gao³

et al. 2021

J. Micromech. Microeng.

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High frequency printed circuit board (PCB), as the significant support for 5G technology, has been receiving intense attention from the increasing number of scholars. Concerning precision fabrication of high frequency PCBs, micro hole drilling is deemed as one of the extremely crucial challenges. In this study, the coated drill bits’ wear and micro hole quality were investigated through the drilling experiments of high frequency PCBs. Results showed that two kinds of coated drill bits exhibited well in terms of hole registration accuracy. Using diamond like carbon coated drill bits could obtain fewer burrs than drilled with diamond coated drill bits before drilling 200 holes, but the burr height increased very slowly with the increment of hole number when using diamond coated drill bits. Taking the combination of aluminum sheet and phenolic aldehyde board as the entry board was conducive to obtaining less burr, and the micro drill bits with helix angles of 40° and 42° were contributed to achieving less burr too. Additionally, decreasing the feed rate could lessen the hole blocking.

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Modeling and optimization of the flute profile of micro-drill

Cited by 15 publications

References 18 publications

Research on the Drilling Performance of a Helical Point Micro Drill with Different Geometry Parameters

Research on the Drilling Performance of a Helical Point Micro Drill with Different Geometry Parameters

An optimized calculation method of the grinding wheel profile for the helical flute grinding

Micro hole drilling of high frequency printed circuit board containing hard fillers

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