An experimental investigation of micro-machinability of copper 101 using tungsten carbide micro-endmills

Filiz, Sinan; Conley, Caroline M.; Wasserman, Matthew B.; Özdoğanlar, O. Burak

doi:10.1016/j.ijmachtools.2006.09.024

Cited by 253 publications

(153 citation statements)

References 31 publications

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“…3b, d, cutting tool corner fracture can be observed after machining both Mg/Ti and TiB 2 MMCs. This type of fracture can be found during several studies related to tool wear in micro-milling of difficult-to-cut materials [26][27][28]. Consequently, the machining accuracy and surface finish could be affected.…”

Section: Tool Wearmentioning

confidence: 91%

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Teng

Huo

Wong

et al. 2016

Int J Adv Manuf Technol

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As a composite material with combination of low weight and high engineering strength, metal matrix composites (MMCs) have been utilised in numerous applications such as aerospace, automobile, and bioengineering. However, MMCs are recognised as difficult-to-cut materials due to their improved strength and high hardness of the reinforcing particles. This paper presents an experimental investigation on micro-machinability of Mg-based MMCs reinforced with Ti and TiB 2 nano-sized particles. The tool wear of AlTiN-coated micro-end mills was investigated. Both abrasive and chip adhesion effect were observed on the main cutting edges, whilst the reinforcement materials and volume fraction play an important role in determining the wear type and severity. The influence of cutting parameters on the surface morphology and cutting force was studied. According to analysis of variance (ANOVA), depth of cut and spindle speed have significant effect on the surface roughness. The specific cutting energy, surface morphology and the minimum chip thickness was obtained and characterised with the aim of examining the size effect. Furthermore, higher cutting force and worse machined surface quality were obtained at the small feed per tooth ranging from 0.15 to 0.5 μm/tooth indicating a strong size effect. Overall, Mg/TiB 2 MMCs exhibit better machinability.

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Section: Tool Wearmentioning

confidence: 91%

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Teng

Huo

Wong

et al. 2016

Int J Adv Manuf Technol

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“…Cutting, ploughing, or slipping phenomena will occur, predominated by this ratio, and will eventually influence machining processes such as surface roughness and burr formation. In previous ultra-precision machining studies, numerous researchers have investigated this size effect, and the critical minimum chip thickness was reported to be around 10-40 per cent of cutting edge radius [5,[27][28][29][30]. WC micro tools used in this work have a cutting edge radius in the range of 3-6 mm measured by a scanning election microscope (SEM) for the same batch of micro tools, whereas CVD diamond and single-crystal diamond micro tools have a cutting edge radius of 0.2 mm as quoted by the manufacturer.…”

Section: Surface Roughnessmentioning

confidence: 99%

Experimental investigation on micromilling of oxygen-free, high-conductivity copper using tungsten carbide, chemistry vapour deposition, and single-crystal diamond micro tools

Huo¹,

Cheng²

2010

Proceedings of the Institution of Mechanical Engineers, Part B:

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Insufficient experimental data from various micro tools limit industrial application of the micromilling process. This paper presents an experimental comparative investigation into micromilling of oxygen-free, high-conductivity copper using tungsten carbide (WC), chemistry vapour deposition (CVD) diamond, and single-crystal diamond micromilling tools at a uniform 0.4 mm diameter. The experiments were carried out on an ultra-precision micromilling machine that features high dynamic accurate performance, so that the dynamic effect of the machine tool itself on the cutting process can be reduced to a minimum. Micromachined surface roughness and burr height were characterized using white light interferometry, a scanning electron microscope (SEM), and a precision surface profiler. The influence of variation of cutting parameters, including cutting speeds, feedrate, and axial depth of cut, on surface roughness and burr formation were analysed. The experimental results show that there exists an optimum feedrate at which best surface roughness can be achieved. Optical quality surface roughness can be achieved with CVD and natural diamond tools by carefully selecting machining conditions, and surface roughness, R a , of the order of 10 nm can also be obtained when using micromilling using WC tools on the precision micromilling machine.

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“…In the current era of manufacturing, there is a great demand for micro-scale devices and components which have complex features and are manufactured from many different materials [1]. Micro-scale parts are utilized in a variety of fields, including the aerospace, automotive, medical, and precision die and mold manufacturing industries [2].…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Tool Path Strategy and Cooling Condition Effects on the Cutting Force and Surface Quality in Micromilling Operations

Köklü

Basmacı

2017

Metals

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Abstract:Compared to milling on a macro scale, the micromilling process has several cumbersome points that need to be addressed. Rapid tool wear and fracture, severe burr formation, and poor surface quality are the major problems encountered in the micromilling process. This study aimed to reveal the effect of cutting path strategies on the cutting force and surface quality in the micromilling of a pocket. The hatch zigzag tool path strategy and the contour climb tool path strategy under different cooling conditions (e.g., dry, air blow, and flood coolant) at fixed cutting parameters. The micromilling tests revealed that better results were obtained with the use of the contour tool path strategy in terms of cutting forces (by up to~43% compared to the dry condition) and surface quality (by up to~44% compared to the air blow condition) when compared to the hatch tool path strategy. In addition, the flood coolant reduces the cutting temperature and eliminates chips to significantly enhance the quality of the micro milled surface.

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An experimental investigation of micro-machinability of copper 101 using tungsten carbide micro-endmills

Cited by 253 publications

References 31 publications

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Experimental investigation on micromilling of oxygen-free, high-conductivity copper using tungsten carbide, chemistry vapour deposition, and single-crystal diamond micro tools

Evaluation of Tool Path Strategy and Cooling Condition Effects on the Cutting Force and Surface Quality in Micromilling Operations

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