Optimization of cutting parameters in micro-milling is an important measure to improve surface quality and machining efficiency of the workpiece. Investigation of micro-milling forces prediction plays a positive role in improving machining capacity. To predict micro-milling forces and optimize micro-milling cutting parameters (per-feed tooth (fz), axial cutting depth (ap), spindle speed (n) and tool extended length (l)), a rotatable center composite experiment of micro-milling straight micro-groove in the workpiece of Al7075-T6 were designed, based on second-order response surface methods. According to the experiment results, the least square method was used to estimate the regression coefficient corresponding to the cutting parameters. Simultaneously, the response prediction model of micro-milling was established and successfully coincide the predicted values with the experiment values. The significance of the regression equation was tested by analysis of variance, and the influence of micro-milling cutting parameters on force and top burrs morphology was studied. The experiment results show that in a specific range of cutting parameters, ap and fz have a significant linear relation with the micro-milling force and the top burrs width. According to the optimal response value, the optimized cutting parameters for micro-milling obtained as: n is 11,393 r/min, fz is 6 µm/z, ap is 11 μm and l is 20.8 mm. The research results provide a useful reference for the selection of cutting parameters for micro-milling.
In this study, type Ib, type IIa, and type IIb synthetic diamonds tools were used for the ultra-precision machining (UPM) of copper. Raman spectroscopy showed that the diamond cutting tools used in these experiments exhibited high-quality sp3 structure and little residual stress in the diamond lattice. Type IIb diamond cutting tools showed higher durability and better UPM performance than the other types of diamond cutting tools. Chemical wear was deemed significant with respect to the cutting tools’ wear in this UPM experiment. Higher durability and enhanced UPM performance could be attributed to the higher thermal and chemical stabilities of the type IIb diamond cutting tool.
In the field of single-point diamond turning (SPDT), machining ferrous metal is an important research topic with promising application. For SPDT of ferrous metal, the influence of lubricant on the workpiece surface morphology remains to be studied. In this study, three lubricant machining environments were selected to carry out specific control experiments. The machined surface morphology and cutting force in different lubricant machining environments were analyzed. The experiment results showed that the lubricant environment will have significant impacts on the quality of the machined surface morphology of ferrous metal. In the environment of minimum quantity lubrication machining (MQLM-oil), better machined surface quality can be obtained than that in ordinary dry machining (ODM) and high-pressure gas machining (HGM). Furthermore, the cutting force captured in the ODM and HGM environment increased with the increase of the cutting depth, while the cutting force in the MQLM-oil environment remained almost unchanged. That indicates MQLM-oil can suppress the formation of hard particles to improve the machining quality.
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