Modeling the Influence of Tool Deflection on Cutting Force and Surface Generation in Micro-Milling

Huo, Dehong; Chen, Wanqun; Teng, Xiangyu; Lin, Chao; Yang, Kai

doi:10.3390/mi8060188

Cited by 35 publications

(16 citation statements)

References 19 publications

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“…Moreover, MM tool deflection is higher at a small scale, due to its lower stiffness in comparison to conventional milling tools. Hence the machining accuracy should be considered for the MM process , especially with hard‐to‐cut materials . With these the effects of cutting forces, temperature, machine vibration, and tool deflection are intensified and this may lead to the cutting tool suffering premature wear or earlier failure .…”

Section: Surface Structuring Technologiesmentioning

confidence: 99%

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Feistauer

Santos

Amancio‐Filho

2018

Polymer Engineering & Sci

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Constant efforts to reduce the structural weight of transportation systems as a solution to control emission levels are currently shaping the way modern cars and airplanes are designed and manufactured. Increased attention has been given to innovative metal–composites multi‐material concepts for the production of lightweight structures. However, the nature of these very dissimilar materials makes their joining a rather complicated task. Recently several technologies have been proposed to overcome process limitation and increase the load transfer between metal and composite in hybrid structures. One of the promising solutions is a new concept known as direct assembling with through‐the‐thickness reinforcements. In this concept, the composite material of a hybrid joint is directly assembled upon a surface‐structured metallic part. Features structured on the metallic part, by a manufacturing phase, act as a through‐the‐thickness reinforcement improving the out‐of‐plane strength and load transfer capabilities of such joints. The current status and state‐of‐art direct assembling technologies are reviewed in this article. Examples of reviewed metal structuring techniques include micromachining, stamping, Surfi‐Sculpt, additive manufacturing, cold metal transfer, and metal injection molding structuring. Direct assembling techniques addressed in this article are vacuum‐assisted resin infusion, resin transfer molding, prepreg/autoclave assembly, and ultrasonic joining. POLYM. ENG. SCI., 59:661–674, 2019. © 2018 The Authors. Polymer Engineering & Science published by Wiley Periodicals, Inc. on behalf of Society of Plastics Engineers.

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Section: Surface Structuring Technologiesmentioning

confidence: 99%

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Feistauer

Santos

Amancio‐Filho

2018

Polymer Engineering & Sci

View full text Add to dashboard Cite

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“…The modern instrument base (vibroacoustic and acoustic-emissive sensors) makes it possible to adequately predict and identify the brittle fracturing process by collecting and processing the diagnostic information from the cutting zone [17][18][19]. However, visualization of the cutting zone is practically impossible due to the specific nature of metalworking, and all conclusions made are based mainly on the results of mathematical modeling [20][21][22][23][24].…”

Section: Introductionmentioning

confidence: 99%

The Role of Thin-Film Vacuum-Plasma Coatings and Their Influence on the Efficiency of Ceramic Cutting Inserts

et al. 2018

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The main problem with ceramics used in cutting tools is related to the unpredictable failures caused by the brittle fracturing of ceramic inserts, which is critical for the intermittent milling of cyclic loading. A 125-mm-diameter eight-toothed end mill, with a mechanical fastening of ceramic inserts, was used as a cutting tool for milling hardened steel (102Cr6). For the experiments, square inserts of the Al2O3 + SiC ceramic were used and compared with the samples made of Al2O3 + TiC to confirm the obtained results. The samples were coated with diamond-like coating (DLC), TiZrN, and TiCrAlN coatings, and their bending strength and adhesion were investigated. Investigations into the friction coefficient of the samples and operational tests were also carried out. The effect of smoothing the microroughness and surface defects in comparison with uncoated inserts, which are characteristic of the abrasive processing of ceramics, was investigated and analyzed. The process developed by the authors of the coating process allows for the cleaning and activation of the surface of ceramic inserts using high-energy gas atoms. The impact of these particles on the cutting edge of the insert ensures its sharpening and reduces the radius of curvature of its cutting edges.

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“…Despite the many advantages of micro-milling, there are still challenges to overcome, especially in the case of dealing with brittle and hard materials, such as ceramics. Firstly, the cutting force can be relatively higher, so stiffer miniature/micro mills are required in order to prevent tool breakage and deflection, which have a negative influence on the cutting process [ 22 , 23 ]. Furthermore, the hardness and abrasive resistance of traditional tungsten carbide tool materials is insufficient for machining hardened ceramics.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on Ductile Mode Micro-Milling of ZrO2 Ceramics with Diamond-Coated End Mills

et al. 2018

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ZrO2 ceramics are currently used in a broad range of industrial applications. However, the machining of post-sintered ZrO2 ceramic is a difficult task, due to its high hardness and brittleness. In this study, micro-milling of ZrO2 with two kinds of diamond-coated end mills has been conducted on a Kern MMP 2522 micro-milling center (Kern Microtechnik GmbH, Eschenlohe, Germany). To achieve a ductile mode machining of ZrO2, the feed per tooth and depth of cut was set in the range of a few micrometers. Cutting force and machined surface roughness have been measured by a Kistler MiniDynamometer (Kistler Group, Winterthur, Switzerland) and a Talysurf 120 L profilometer (Taylor Hobson Ltd., Leicester, UK), respectively. Machined surface topography and tool wear have been examined under SEM. Experiment results show that the material can be removed in ductile mode, and mirror quality surface with Ra low as 0.02 μm can be achieved. Curled and smooth chips have been collected and observed. The axial cutting force Fz is always bigger than Fx and Fy, and presents a rising trend with increasing of milling length. Tool wear includes delamination of diamond coating and wear of tungsten carbide substrate. Without the protection of diamond coating, the tungsten carbide substrate was worn out quickly, resulting a change of tool tip geometry.

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Modeling the Influence of Tool Deflection on Cutting Force and Surface Generation in Micro-Milling

Cited by 35 publications

References 19 publications

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

The Role of Thin-Film Vacuum-Plasma Coatings and Their Influence on the Efficiency of Ceramic Cutting Inserts

Experimental Investigation on Ductile Mode Micro-Milling of ZrO2 Ceramics with Diamond-Coated End Mills

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