What micro-mechanical testing can reveal about machining processes

Axinte, Dragoş; Huang, Han; Yan, Jiwang; Liao, Zhirong

doi:10.1016/j.ijmachtools.2022.103964

Cited by 39 publications

(2 citation statements)

References 104 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…As the feed per tooth rises, the actual undeformed chip thickness (UCT) during each cutting process (i.e., every rotation of the milling cutter) also increases synchronously [49]. Once the actual UCT exceeds the critical UCT of brittle-to-ductile transition, micro-cracks will engage in material removal behaviors [49,50] and occur on machined surfaces, as shown in Figure 4b-d. These micro-cracks could prove a mixed material removal mode or ductile-to-brittle transition occurred on these machined surfaces.…”

Section: Analysis Of Micro-milled Kdp Surface Morphologiesmentioning

confidence: 99%

Fractal Analysis on Machined Surface Morphologies of Soft-Brittle KDP Crystals Processed by Micro Ball-End Milling

et al. 2023

Self Cite

View full text Add to dashboard Cite

The micro-defects on KH2PO4 (KDP) optic surfaces are mainly repaired by the micro-milling technique, while it is very easy to introduce brittle cracks on repaired surfaces, as KDP is soft and brittle. To estimate machined surface morphologies, the conventional method is surface roughness, but it fails to distinguish ductile-regime machining from brittle-regime machining directly. To achieve this objective, it is of great significance to explore new evaluation methods to further characterize machined surface morphologies. In this study, the fractal dimension (FD) was introduced to characterize the surface morphologies of soft-brittle KDP crystals machined by micro bell-end milling. The 3D and 2D fractal dimensions of the machined surfaces and their typical cross-sectional contours have been calculated, respectively, based on Box-counting methods, and were further discussed comprehensively by combining the analysis of surface quality and textures. The 3D FD is identified to have a negative correlation with surface roughness (Sa and Sq), meaning the worse the surface quality the smaller the FD. The circumferential 2D FD could quantitively characterize the anisotropy of micro-milled surfaces, which could not be analyzed by surface roughness. Normally, there is obvious symmetry of 2D FD and anisotropy on the micro ball-end milled surfaces generated by ductile-regime machining. However, once the 2D FD is distributed asymmetrically and the anisotropy becomes weaker, the assessed surface contours would be occupied by brittle cracks and fractures, and corresponding machining processes will be in a brittle regime. This fractal analysis would facilitate the accurate and efficient evaluation of the repaired KDP optics by micro-milling.

show abstract

Section: Analysis Of Micro-milled Kdp Surface Morphologiesmentioning

confidence: 99%

Fractal Analysis on Machined Surface Morphologies of Soft-Brittle KDP Crystals Processed by Micro Ball-End Milling

et al. 2023

Self Cite

View full text Add to dashboard Cite

show abstract

“…For many years, micromachining technology has dedicated significant efforts to investigating the microscopic scale material removal process [ 10 , 11 ]. Recently, vibration-assisted micro machining has arisen as a promising approach for accurate and flexible surface texturing [ 12 , 13 , 14 ].…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Song,

Zhang,

Jing

et al. 2024

Micromachines

View full text Add to dashboard Cite

Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the effects of tool edge geometry, minimum uncut chip thickness (MUCT), and material elastic recovery. The surface texture formation under different machining parameters is simulated and analyzed through mathematical modeling. Two typical surface morphologies can be generated: wave-type and fish scale-type textures, depending on the phase difference between tool paths. A 2-degrees-of-freedom (2-DOF) vibration stage is also developed to provide vibration along the feed and cross-feed directions during micro-milling process. Micro-milling experiments on copper were carried out to verify the ability to fabricate controlled surface textures using the vibration stage. The simulated and experimentally generated surfaces show good agreement in geometry and dimensions. This work provides an accurate analytical model for vibration-assisted micro-milling surface generation and demonstrates its feasibility for efficient, flexible texturing.

show abstract

Unveiling the temperature-dependent deformation mechanisms of single crystal gallium nitride in nanoscratching

Wang,

Rao,

et al. 2025

Applied Surface Science

View full text Add to dashboard Cite

What micro-mechanical testing can reveal about machining processes

Cited by 39 publications

References 104 publications

Fractal Analysis on Machined Surface Morphologies of Soft-Brittle KDP Crystals Processed by Micro Ball-End Milling

Fractal Analysis on Machined Surface Morphologies of Soft-Brittle KDP Crystals Processed by Micro Ball-End Milling

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Unveiling the temperature-dependent deformation mechanisms of single crystal gallium nitride in nanoscratching

Contact Info

Product

Resources

About