Analysis of cutting force and vibration at micro-milling of a hardened steel

Balázs, Barnabás Zoltán; Geier, Norbert; Pereszlai, Csongor; Poór, Dániel István; Takács, Márton

doi:10.1016/j.procir.2021.03.025

Cited by 9 publications

(5 citation statements)

References 32 publications

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“…A purpose-designed tool can remove material from the workpiece mechanically through micro-channels. Mechanical micro-machining is capable of achieving unique features and small tolerances with various materials, including hardened steel, Inconel, aluminum, and polymer composites [ 47 , 48 , 73 , 74 ]. However, there are real-time challenges of chip removal in micro-sizes, tool deformation, burr formation, and vibrations [ 47 , 75 , 76 ].…”

Section: Alternative Micro-feature Fabrication Processesmentioning

confidence: 99%

“…Mechanical micro-machining is capable of achieving unique features and small tolerances with various materials, including hardened steel, Inconel, aluminum, and polymer composites [ 47 , 48 , 73 , 74 ]. However, there are real-time challenges of chip removal in micro-sizes, tool deformation, burr formation, and vibrations [ 47 , 75 , 76 ]. Figure 4 shows some of the micro-milling procedures: down-, groove-, and up-milling, burr formation, and the problem of tool deflection while milling thin-walled structures.…”

Section: Alternative Micro-feature Fabrication Processesmentioning

confidence: 99%

“… ( a ) Schematic of micro-channel machining [ 47 ], ( b ) formation of burrs [ 76 ] and ( c ) deflection of micro-tool [ 75 ]. Copyright granted by Elsevier and Optica Publishing Group.…”

Section: Figurementioning

confidence: 99%

“…The concept of localized material removal results in better surface quality and finish. This is in contrast to other manufacturing processes, such as micro-milling, UV lithography, laser polishing, and chemical etching, none of which can provide the same accuracy in shaping micro-features, due to the limitations of tool size and wear, the rectilinear nature of light, and surface defects and stresses that are induced at tool–micro-feature interfaces [ 47 , 48 , 49 , 50 , 51 , 52 ]. Moreover, electrochemical polishing is capable of removing material at controlled rates using various waveforms: pulsed current (PC) and pulse reverse pulse current (PPR) can help maintain the structural integrity of micro-scale features [ 53 , 54 , 55 , 56 , 57 ].…”

Section: Introductionmentioning

confidence: 99%

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Electropolishing and Shaping of Micro-Scale Metallic Features

2022

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Electropolishing (EP) is most widely used as a metal finishing process. It is a non-contact electrochemical process that can clean, passivate, deburr, brighten, and improve the biocompatibility of surfaces. However, there is clear potential for it to be used to shape and form the topology of micro-scale surface features, such as those found on the micro-applications of additively manufactured (AM) parts, transmission electron microscopy (TEM) samples, micro-electromechanical systems (MEMs), biomedical stents, and artificial implants. This review focuses on the fundamental principles of electrochemical polishing, the associated process parameters (voltage, current density, electrolytes, electrode gap, and time), and the increasing demand for using environmentally sustainable electrolytes and micro-scale applications. A summary of other micro-fabrication processes, including micro-milling, micro-electric discharge machining (EDM), laser polishing/ablation, lithography (LIGA), electrochemical etching (MacEtch), and reactive ion etching (RIE), are discussed and compared with EP. However, those processes have tool size, stress, wear, and structural integrity limitations for micro-structures. Hence, electropolishing offers two-fold benefits of material removal from the metal, resulting in a smooth and bright surface, along with the ability to shape/form micro-scale features, which makes the process particularly attractive for precision engineering applications.zx3

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Section: Alternative Micro-feature Fabrication Processesmentioning

confidence: 99%

Section: Alternative Micro-feature Fabrication Processesmentioning

confidence: 99%

“… ( a ) Schematic of micro-channel machining [ 47 ], ( b ) formation of burrs [ 76 ] and ( c ) deflection of micro-tool [ 75 ]. Copyright granted by Elsevier and Optica Publishing Group.…”

Section: Figurementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Electropolishing and Shaping of Micro-Scale Metallic Features

2022

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“…The full factorial experimental design was applied for both the simulations and the experiments. The applied factors and their levels can be seen in table 2, which are based on the proposed cutting parameters made by the tool manufacturer, and the previous research works of the authors [12,13].…”

Section: Experimental Setup and Designmentioning

confidence: 99%

Finite element simulation of micro-milling of hardened tool steel

Balázs

Takács

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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The demand for miniature components has been growing steadily in recent years. One of the most important technologies to produce such small components is micro-milling. Although the technology is highly researched, there are still many difficulties due to the size reduction, which makes the finite element simulation, as well as the exploration of cutting process challenging. The aim of the research was to investigate the micro-milling process, especially those features, that can be measured very complicated due to the small sizes at the experiments, such as the cutting temperature, and stresses, by means of finite element simulation. The results show that the cutting temperatures are smaller than in the case of conventional size machining, moreover, the stresses do not show significant changes during the cutting edge impact. Finally, the results were validated by the experimental results through comparing cutting force components, which shows a good agreement.

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Investigation on self-fabricated PCD cutter and its application in deep-and-narrow micro-grooves

Han

Kong

et al. 2022

Int J Adv Manuf Technol

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Analysis of cutting force and vibration at micro-milling of a hardened steel

Cited by 9 publications

References 32 publications

Electropolishing and Shaping of Micro-Scale Metallic Features

Electropolishing and Shaping of Micro-Scale Metallic Features

Finite element simulation of micro-milling of hardened tool steel

Investigation on self-fabricated PCD cutter and its application in deep-and-narrow micro-grooves

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