Built-up-edge effects on surface deterioration in micromilling processes

Wang, Z.; Kovvuri, V.; Araujo, Anna Carla; Bacci, M.; Hung, Wayne; Bukkapatnam, Satish T. S.

doi:10.1016/j.jmapro.2016.03.016

Cited by 46 publications

(23 citation statements)

References 27 publications

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“…Similar results were also observed in Oliaei and Karpat [19] in micro turning experiments. Our experimental results are comparable to surface roughness values reported in Wang et al [12] where the focus was finish micro milling experiments. It means that comparable results can be obtained in terms of surface roughness with the tailored tools.…”

Section: Investigation Of Micro Milling Process Outputs In the Presensupporting

confidence: 91%

“…Thepsonti and Özel [10] observed BUE formation in micro milling of titanium alloy Ti6AL4V. Recently, Kovvuri et al [11] and Wang et al [12] studied the influence of BUE while machining 316L stainless steel and reported that BUE is mainly responsible for surface roughness deterioration in the finish micro milling process. They showed that when BUE is not present, theoretical surface roughness models yield acceptable predictions.…”

Section: Introductionmentioning

confidence: 99%

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

Oliaei

2017

Precision Engineering

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Built-up edge (BUE) is generally known to cause surface finish problems in the micro milling process. The loose particles from the BUE may be deposited on the machined surface, causing surface roughness to increase. On the other hand, a stable BUE formation may protect the tool from rapid tool wear, which hinders the productivity of the micro milling process. Despite its common presence in practice, the influence of BUE on the process outputs of micro milling has not been studied in detail. This paper investigates the relationship between BUE formation and process outputs in micro milling of titanium alloy Ti6Al4V using an experimental approach. Micro end mills used in this study are fabricated to have a single straight edge using wire electrical discharge machining. An initial experimental effort was conducted to study the relationship between micro cutting tool geometry, surface roughness, and micro milling process forces and hence conditions to form stable BUE on the tool tip have been identified. The influence of micro milling process conditions on BUE size, and their combined effect on forces, surface roughness, and burr formation is investigated. Long-term micro milling experiment was performed to observe the protective effect of BUE on tool life. The results show that tailored micro cutting tools having stable BUE can be designed to machine titanium alloys with long tool life with acceptable surface quality.

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Section: Investigation Of Micro Milling Process Outputs In the Presensupporting

confidence: 91%

Section: Introductionmentioning

confidence: 99%

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

Oliaei

2017

Precision Engineering

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“…The results correlate with the findings of Jaffery et al [15]. Recently, Wang et al [23] showed that peaks on the surface due to BUE hinder the ability to predict surface quality in micromilling.…”

Section: Surface Texture Investigationsupporting

confidence: 88%

Uncertainty analysis of force coefficients during micromilling of titanium alloy

Gözü

2017

Int J Adv Manuf Technol

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Predicting process forces in micromilling is difficult due to complex interaction between the cutting edge and the work material, size effect, and process dynamics. This study describes the application of Bayesian inference to identify force coefficients in the micromilling process. The Metropolis-Hastings (MH) algorithm Markov chain Monte Carlo (MCMC) approach has been used to identify probability distributions of cutting, edge, and ploughing force coefficients based on experimental measurements and a mechanistic model of micromilling. The Bayesian inference scheme allows for predicting the upper and lower limits of micromilling forces, providing useful information about stability boundary calculations and robust process optimization. In the first part of the paper, micromilling experiments are performed to investigate the influence of micromilling process parameters on machining forces, tool edge condition, and surface texture. Under the experimental conditions used in this study, built-up edge formation is observed to have a significant influence on the process outputs in micromilling of titanium alloy Ti6Al4V. In the second part, Bayesian inference was explained in detail and applied to model micromilling force prediction. The force predictions are validated with the experimental measurements. The paper concludes with a discussion of the effectiveness of employing Bayesian inference in micromilling force modeling considering special machining cases.

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“…For example, peeling of tool coating might be due to coating defects or mechanical mechanism when a large gradient of stress exists across a Figure 6. Built-up-edge and its effects [12]. thick coating layer; the loosen coating particles then rub and cause mechanical abrasive wear on a tool.…”

Section: Tool Damagementioning

confidence: 99%

“…Each range plot shows the maximum, minimum, and average of 15 measurements. Micromilling 316L stainless steel [12]. Figure 13.…”

Section: Micromillingmentioning

confidence: 99%

Micromachining of Advanced Materials

Hung¹,

Corliss²

2019

Micromachining

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Market needs often require miniaturized products for portability, size/weight reduction while increasing product capacity. Utilizing additive manufacturing to achieve a complex and functional metallic part has attracted considerable interests in both industry and academia. However, the resulted rough surfaces and low tolerances of as-printed parts require additional steps for microstructure modification, physical and mechanical properties enhancement, and improvement of dimensional/form/surface to meet engineering specifications. Micromachining can (i) produce miniature components or microfeatures on a larger component, and (ii) enhance the quality of additively manufactured metallic components. This chapter suggests the necessary requirements for successful micromachining and cites the research studies on micromachining of metallic materials fabricated by either traditional route or additive technique. Micromachining by nontraditional techniques-e.g., ion/electron beam machining-are beyond the scope of this chapter. The chapter is organized as following:

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Built-up-edge effects on surface deterioration in micromilling processes

Cited by 46 publications

References 27 publications

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

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

Uncertainty analysis of force coefficients during micromilling of titanium alloy

Micromachining of Advanced Materials

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