Study on Surface Roughness in Micro End Milling of Mold Material

Abstract

The effects of cutting conditions on the surface roughness in a micro-end-milling process of a mold material are described in this paper. Micro-end-milling operations were performed under different cutting conditions such as feed rate and depth of cut, in order to investigate the factors that had the greatest influence on the finished surface during micro-end-milling. It was revealed that the surface roughness begins to deteriorate when the radial depth of the cut exceeds the tool radius. In addition, it was found that this phenomenon is peculiar to micro-end-milling processes.

Surface Finish of Ball-End Milled Microchannels

“…The experimental data and theoretical prediction show a smoother surface should be obtainable with low chip load; however, this contradicts with another study that found feed rate, therefore chip load, does not affect surface finish [9]. It is postulated that a wrong combination of large tool edge radius and shallow depth of cut could smear the surface and does not truly reflect the contribution of chip load.…”

“…In a study of surface finish of micromilled cold worked SLD11 steel using TiAlN coated WC ϕ900µm flat end mills, it was found that surface finish does not depend on feed as it does in conventional macromilling. The finish is not affected by axial depth of cut, but radial depth of cut has the most significant impact if there is any chattering [9]. Other authors [10] investigated the influence of the cutting fluid and cutting speed on the surface roughness during micro milling of Ti6Al4V with WC flat end mill.…”

The Effect of Hard Milling on Surface Finish of Medium Carbon Steel

“…In previous study, factors of milling can be affected to quality of surface such as feed, speed, depth of cut, cutting tool, mechanical load, thermal load, and abrasive load. The effect of milling parameters on surface roughness could be reported on previous study [1][2][3][4][5][6][7][8]. In milling operation, factors affected to surface finish were studied for steel such as high strength steel [1], mold steel [2], stainless steel [3] and carbon steel [4].…”

“…The effect of milling parameters on surface roughness could be reported on previous study [1][2][3][4][5][6][7][8]. In milling operation, factors affected to surface finish were studied for steel such as high strength steel [1], mold steel [2], stainless steel [3] and carbon steel [4]. The others material has been studied such as cobalt-based alloy [5], titanium alloy [6], and polymer [7].…”

The Study of Surface Finish in Face Milling of Stainless Steel: AISI 304

“…Previous study reported that effect of milling parameters in various process on surface roughness. Such as, the milling operation and factors affected to finished surface of medium carbon steel [2], aluminum [3], cobalt-based alloy [4], titanium alloy [5,6], mold steel [7] and polymer [8].…”