Advances in micro milling: From tool fabrication to process outcomes

Chen, Ni; Li, Hao Nan; Wu, Jinming; Li, Zhenjun; Li, Liang; Liu, Gongyu; He, Ning

doi:10.1016/j.ijmachtools.2020.103670

Cited by 169 publications

(53 citation statements)

References 204 publications

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“…There is an increased demand for the miniaturization of components in industrial products, which has many functions and requires acceptable dimensional accuracy [1]. Micromachining is a process of producing miniature parts and components in mass production [2].…”

Section: Introductionmentioning

confidence: 99%

Effect of Tool Coating and Cutting Parameters on Surface Roughness and Burr Formation during Micromilling of Inconel 718

Atif

Gupta

Mikołajczyk

et al. 2021

Metals

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Surface roughness and burr formation are among the most important surface quality metrics which determine the quality of the fabricated parts. High precision machined microparts with complex features require micromachining process to achieve the desired yet stringent surface finish and dimensional accuracy. In this research, the effect of cutting speed (m/min), feed rate (µm/tooth), depth of cut (µm) and three types of tool coating (AlTiN, nACo and TiSiN) were analyzed to study their effect on surface roughness and burr formation during the micromachining of Inconel 718. The analysis was carried out using an optical profilometer, scanning electron microscope and statistical technique. Machining tests were performed at low speed with a feed rate (µm/tooth) below the cutting-edge radius for 10 mm cutting length using a carbide tool of 0.5 mm diameter on a CNC milling machine. From this research, it was determined that the depth of cut was the main factor affecting burr formation, while cutting velocity was the main factor affecting the surface roughness. In addition, cutting tool coating did not significantly affect either surface roughness or burr formation due to the difference in coefficient of friction. The types of burr formed during micromilling of Inconel 718 were mainly influenced by the depth of cut and feed rate (µm/tooth) and were not affected by the cutting velocity. It was also concluded that the results for the surface finish at low-speed machining are comparable to that of transition and high-speed machining, while the burr width found during confirmation experiments at low-speed machining was also within an acceptable range.

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Section: Introductionmentioning

confidence: 99%

Effect of Tool Coating and Cutting Parameters on Surface Roughness and Burr Formation during Micromilling of Inconel 718

Atif

Gupta

Mikołajczyk

et al. 2021

Metals

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“…Similar results can be found from Figure 15 b, that by increasing the number of workpieces distributed on the workpiece fixture, as shown in Figure 12 b, the material removal mass for each position of workpiece is still stable with irrational number of i pw = 0.3819…. Therefore, by qualitatively and quantitatively analyzing the surface morphology and characteristics it is found that the surface quality, including surface roughness and material removal uniformity, has been significantly improved by using the irrational number of i pw in the single-side planetary lapping process, and it could reduce the cost and time for the further ultra-precision polishing process with advanced robotics technology [ 20 , 21 , 22 , 23 , 24 , 25 ].…”

Section: Resultsmentioning

confidence: 99%

Surface Quality Improvement by Using a Novel Driving System Design in Single-Side Planetary Abrasive Lapping

Chen

Wen

Lu³

et al. 2021

Materials

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For the traditional single-side planetary abrasive lapping process particle trajectories passing over the target surface are found to be periodically superposed due to the rational rotation speed ratio of the lapping plate to workpiece that could affect the material removal uniformity and hence its surface quality. This paper reports on a novel driving system design with combination of the tapered roller and contact roller to realize the irrational rotation speed ratio of the lapping plate to workpiece in the single-side planetary abrasive lapping process for the improvement of surface quality. Both of the numerical and experimental investigations have been conducted to evaluate the abrasive lapping performance of the novel driving system. It has been found from the numerical simulation that particle trajectories would theoretically cover the whole target surface if the lapping time is long enough due to their non-periodic characteristics, which can guarantee the uniformity of material removal from the surface of workpiece with relatively high surface quality. The encouraging experimental results underline the potential of the novel driving system design in the application of the single-side planetary abrasive lapping for the improvement of the surface quality in terms of surface roughness and material removal uniformity.

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“…Unlike the constant undeformed chip thickness (UCT) and direction of cutting speed in orthogonal micro-cutting, both vary in a time-dependent manner in micro-milling. The micro-milling process can be considered as the composition of varied orthogonal micro-cutting in the time domain [63][64][65]. In end micro-milling (Figure 15a), the thickness (i) initially increases from zero, (ii) reaches the maximum value (approximately equal to the feed per tooth), and (iii) reduces to zero, while in a side micro-milling (Figure 15b), the thickness decreases from maximum to zero.…”

Section: Discussionmentioning

confidence: 99%

Combined Processing of Micro Cutters Using a Beam of Fast Argon Atoms in Plasma

et al. 2021

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We present a new method for coating deposition on micro cutters without an increase in their cutting edges radii caused by the deposition. For this purpose, the cutting edges are sharpened before the coating deposition with a concentrated beam of fast argon atoms. The sharpening decreases the initial radius and, hence, limits its value after the coating deposition. The concentrated beam of fast argon atoms is generated using an immersed in the gas discharge plasma concave grid under a negative high voltage. Ions accelerated from the plasma by the grid pass through the grid holes and are concentrated in the focal point of the grid. As a result of the charge exchange in the space charge sheaths of the grid, they are transformed into fast atoms. A uniform sputtering by the fast atoms of the micro-cutter surface reduces the radius of its cutting edge.

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Advances in micro milling: From tool fabrication to process outcomes

Cited by 169 publications

References 204 publications

Effect of Tool Coating and Cutting Parameters on Surface Roughness and Burr Formation during Micromilling of Inconel 718

Effect of Tool Coating and Cutting Parameters on Surface Roughness and Burr Formation during Micromilling of Inconel 718

Surface Quality Improvement by Using a Novel Driving System Design in Single-Side Planetary Abrasive Lapping

Combined Processing of Micro Cutters Using a Beam of Fast Argon Atoms in Plasma

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