Built-up edge effects on process outputs of titanium alloy micro milling

Oliaei, Samad Nadimi Bavil

doi:10.1016/j.precisioneng.2017.02.019

Cited by 48 publications

(29 citation statements)

References 24 publications

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“…4.2.3, the axial depth of these control slots was also higher. This again is a direct consequence of such a build-up of material [4]. In general, there was again no significant difference seen between the S-800 and the S-1200 slurries in terms of their effect on the cutting force.…”

Section: Toolmentioning

confidence: 89%

“…In micromilling, the burr formation is the result of extensive plastic deformation/plowing of the material [16]. Increase in BUEs has been known to result in an increased burr formation, because the BUEs change the effective rake angle of the tool causing more material to be plowed to the sides of the slot [4]. The volume measurement module on the Alicona Infinite-Focus G5 TM optical profiler was used to calculate the total volume of burr formed on the surface of the slot over the 50 cuts.…”

Section: Burr Volumementioning

confidence: 99%

“…While the last decade has seen significant research efforts dedicated to micromilling, the formation of builtup edges (BUEs) during the machining of materials such as aluminum continues to be a critical bottleneck for this process [2]. This is primarily because the reduced size-scale of machining encountered in micromilling results in the BUEs having a more detrimental impact on key process outcomes such as surface roughness, burr formation, cutting forces, and tool wear [3][4][5][6].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

An In-Process Intervention to Mitigate the Effect of Built-Up Edges in Micromilling

Altman

Nowak

Samuel

2017

Journal of Micro and Nano-Manufacturing

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This paper is focused on developing an in-process intervention technique that mitigates the effect of built-up edges (BUEs) during micromilling of aluminum. The technique relies on the intermittent removal of the BUEs formed during the machining process. This is achieved using a three-stage intervention that consists first of the mechanical removal of mesoscale BUEs, followed by an abrasive slurry treatment to remove the microscale BUEs. Finally, the tool is cleaned using a nonwoven fibrous mat to remove the slurry debris. An on-machine implementation of this intervention technique is demonstrated, followed by a study of its influence on key micromachining outcomes such as tool wear, cutting forces, part geometry, and burr formation. In general, all relevant machining measures are found to improve significantly with the intervention. The key attributes of this intervention that makes it viable for micromachining processes include the following: (i) an experimental setup that can be implemented within the working volume of the microscale machine tool; (ii) no removal of the tool from the spindle, which ensures that the intervention does not change critical process parameters such as tool runout and offset values; and (iii) implementation in the form of canned G-code subroutines dispersed within the regular micromachining operation.

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Section: Toolmentioning

confidence: 89%

Section: Burr Volumementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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An In-Process Intervention to Mitigate the Effect of Built-Up Edges in Micromilling

Altman

Nowak

Samuel

2017

Journal of Micro and Nano-Manufacturing

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“…Guo et al numerically modeled and experimentally studied the micro-milling force of titanium alloy based on tool runout. The micro-milling force model was validated by analyzing the width of the steps on the edge of the groove [12,13]. Zhang simulated the stress field of a flat-faced milling cutter and a 3D complex groove milling cutter using the density function of the milling force as a boundary condition.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Texture Density Distribution of Carbide Alloy Micro-Textured Ball-End Milling Cutter Based on Stress Field

Zheng

Yang

2020

Applied Sciences

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The insertion of micro-textures plays a role in reducing friction and increasing wear resistance of the cutters, which also has a certain impact on the stress field of the cutter during milling. Therefore, in order to study the mechanisms of friction reduction and wear resistance of micro-textured cutters in high speed cutting of titanium alloys, the dynamic characteristics of the instantaneous stress field during the machining of titanium alloys with micro-textured cutters were studied by changing the distribution density of the micro-textures on the cutter. First, the micro-texture insertion area of the ball-end milling cutter was theoretically analyzed. Then, variable density micro-textured ball-end milling cutters and non-texture cutters were used to cut titanium alloy, and the mathematical model of milling force and cutter-chip contact area was established. Then, the stress density functions of different micro-texture density cutters and non-texture cutters were established to simulate the stress fields of variable density micro-textured ball-end milling cutters and non-texture cutters. Finally, the genetic algorithm was used to optimize the variable density distribution of micro-textured cutters in which the instantaneous stress field of the cutters was taken as the optimization objective. The optimal solution for the variable density distribution of the micro-textured cutter in the cutter-chip tight contact area was obtained as follows: the texture distribution densities in the first, second, and third areas are second, and third areas are 0.0905, 0.0712, and 0.0493, respectively.

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“…In this process, the material removal is realised through the use of micro end mills with diameters less than 1 mm. The micro end mills have important contributions to the productivity and accuracy of the micromilling process (Oliaei and Karpat, 2017). They are the most flexible part of micro-cutting system and have the lowest stiffness in the whole micro cutting process chain.…”

Section: Introductionmentioning

confidence: 99%

Modelling and analysis of tool deflections in tailored micro end mills

Oliaei

2019

IJMMS

Self Cite

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The deflection of micro end mills has a detrimental effect on surface quality of the machined micro components and adversely affects the achievable dimensional and geometrical tolerances. In this paper, the analysis and modelling of tool deflections of tailored micro end mills have been considered. The tool deflections are obtained using analytical models as well as finite element simulations and verified using a dedicated measurement setup, which uses a capacitive sensor with a nanometre resolution for static tool deflection measurements. The optimisation of the micro end mill geometry has been performed to determine optimum neck taper angle and transition radius of the single edge micro end mill to have minimum tool deflections. With the developed model, tool failure predictions for a given process parameter set can be performed and it can be used for better micro milling process planning.

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Built-up edge effects on process outputs of titanium alloy micro milling

Cited by 48 publications

References 24 publications

An In-Process Intervention to Mitigate the Effect of Built-Up Edges in Micromilling

An In-Process Intervention to Mitigate the Effect of Built-Up Edges in Micromilling

Optimization of Texture Density Distribution of Carbide Alloy Micro-Textured Ball-End Milling Cutter Based on Stress Field

Modelling and analysis of tool deflections in tailored micro end mills

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