A review of machining theory and tool wear with a view to developing micro and nano machining processes

Robinson, G. W.; Jackson, Mark J.; Whitfield, Michael D.

doi:10.1007/s10853-006-0171-z

Cited by 40 publications

(16 citation statements)

References 50 publications

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“…1 Ceramic coatings have been applied widely, e.g., to gears, 2,3 bearings, 4,5 and machining tools. [6][7][8] The mechanical integrity of the interface region between the ceramic coating and the underlying substrate is critical, as interfacial failures lead to rapid removal of coatings from substrates, often causing catastrophic failures of coated systems as a whole. In the last two decades, quantitative experimental assessment of critical stresses leading to failure of interfacial regions in coating/substrate systems has remained a challenge.…”

Section: Introductionmentioning

confidence: 99%

Measuring critical stress for shear failure of interfacial regions in coating/interlayer/substrate systems through a micro-pillar testing protocol

Zhang

Hutchinson

et al. 2017

J. Mater. Res.

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Section: Introductionmentioning

confidence: 99%

Measuring critical stress for shear failure of interfacial regions in coating/interlayer/substrate systems through a micro-pillar testing protocol

Zhang

Hutchinson

et al. 2017

J. Mater. Res.

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“…10 In addition, current dental drills can reach speeds up to 500,000 rpm and have a runout of above 10 µm, which is usually greater than the chip thickness. 11 To reach the machining accuracy of submicron order, micro-spindles or micro-tools have at least submicron runout. In fact, the spindles with submicron runout are now commercially available.…”

Section: Introductionmentioning

confidence: 99%

Development of a high-speed and precision micro-spindle for micro-cutting

Zhou

Huang

et al. 2014

Int. J. Precis. Eng. Manuf.

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Mechanical micromachining using micro-machine tools is very competitive in manufacturing geometrically complex 3D micro-parts in various engineering materials with advantages of small space, energy-efficient, low equipment production and operation costs. As key components of micro-machine tools, micro-spindles directly determine the performance of micro-machine tools and the application and development of mechanical micromachining technology. This study proposes a novel design concept of the separately spindle and tool and one-piece tool/rotor structure for micro-spindles, whose micro-tool can maintain good rotational accuracy at high rotational speeds. In the principle prototype micro-spindle, an air driven turbine was used as power spindle. The design and optimization of the micro-spindle were conducted. The fabrication and evaluation of the prototype micro-spindle were presented. The results of the principle prototype micro-spindle were analyzed and some efforts for the subsequent micro-spindle were proposed.

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“…The level of precision of the nanomachined features continuously degrades during the machining process as the probe tip inevitably wears resulting in an increase of contact diameter and forces acting on it [3]. Establishing the point at which the tool is considered worn is important, since, after this point, machining results are no longer acceptable [4]. Thus quantification of tool wear to predict the tool life is of great significance.…”

Section: Introductionmentioning

confidence: 99%

Modeling of Tool Wear in Vibration Assisted Nano Impact-Machining by Loose Abrasives

James

Sundaram

2014

International Journal of Manufacturing Engineering

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Vibration assisted nano impact-machining by loose abrasives (VANILA) is a novel nanomachining process that combines the principles of vibration assisted abrasive machining and tip-based nanomachining, to perform target specific nanoabrasive machining of hard and brittle materials. An atomic force microscope (AFM) is used as a platform in this process wherein nanoabrasives, injected in slurry between the workpiece and the vibrating AFM probe which is the tool, impact the workpiece and cause nanoscale material removal. The VANILA process are conducted such that the tool tip does not directly contact the workpiece. The level of precision and quality of the machined features in a nanomachining process is contingent on the tool wear which is inevitable. Initial experimental studies have demonstrated reduced tool wear in the VANILA process as compared to indentation process in which the tool directly contacts the workpiece surface. In this study, the tool wear rate during the VANILA process is analytically modeled considering impacts of abrasive grains on the tool tip surface. Experiments are conducted using several tools in order to validate the predictions of the theoretical model. It is seen that the model is capable of accurately predicting the tool wear rate within 10% deviation.

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A review of machining theory and tool wear with a view to developing micro and nano machining processes

Cited by 40 publications

References 50 publications

Measuring critical stress for shear failure of interfacial regions in coating/interlayer/substrate systems through a micro-pillar testing protocol

Measuring critical stress for shear failure of interfacial regions in coating/interlayer/substrate systems through a micro-pillar testing protocol

Development of a high-speed and precision micro-spindle for micro-cutting

Modeling of Tool Wear in Vibration Assisted Nano Impact-Machining by Loose Abrasives

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