Abstract:The study focuses on micro-milling of a hardened tool steel with micro ball-end mills. The purpose is to observe the capability of a set of these mills to machine hard steels used for tooling applications. Different cutting configurations are here tested in order to evaluate their performance and finally enhance their design in this context. Experimental data, in terms of cutting forces, surfaces integrity and machining errors, is obtained from machining tests on a 40NiCrMo16 hardened steel with 0.5 mm diameter coated tungsten carbide micro-tools. The results allow highlighting some cutting, wear and dynamical phenomena related to the process. They are mainly associated to the types of mill and cutting conditions, as feed or tool/surface inclination. In this paper, the tool geometry and its dynamical behavior are mainly discussed.
This study deals with micro-ball-end milling of a pre-sintered Yttria Tetragonal Zirconia Polycrystal. The aim is to underline the reliability of different coatings while machining this material regularly used in dental and luxury industries. A particular tool configuration – which is identified as critical by the targeted sectors – is tested previously determined stable cutting conditions, for all the chosen coatings. Cutting forces, tool reliability and surface integrity data is obtained by green machining of a 5Y-TZP (tetragonal zirconia polycrystal stabilized by 5%mol of yttrium) with 1 mm diameter tungsten carbide micro-tools coated with two PVD and one CVD coatings (respectively AlCrN, DLC and diamond). The results highlight that the choice of an appropriate coating is mandatory for this type of abrasive ceramics, even if they are partially sintered. Material flow, tool wear and machined surface quality are discussed and correlated.
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