Burr formation mechanism and machining parameter effect in slot micro-milling titanium alloy Ti6Al4V

Zhang, Yabo; Bai, Qingshun; Sun, Yangyang; Li, Donghai

doi:10.1007/s00170-022-10298-w

Cited by 12 publications

(3 citation statements)

References 41 publications

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“…The reduction in the burr has been observed due to a decrease in the uncut chip thickness with an increase in spindle speed. Internal also show the shear front formation, which confirms the burrs are adhesive residual chips as shown in figure 10(b) [42]. Under toolworkpiece extrusion and impact load, the adhesive chips easily escape from the cutting tool and forms the internal burr in the up-milling side.…”

Section: Morphological and Topographical Analyses Of Micro Channelssupporting

confidence: 56%

“…Less interaction time on the up-milling side due to the high relative velocity between the tool and the up-milling side leads to more burr formation on the up-milling side. On the down-milling, as the tool exits the workpiece during each subsequent pass, it leaves burrs and chips along the edge of the slot that vary depending on the material properties [42].…”

Section: Analysis Of Burr Formation Mechanismmentioning

confidence: 99%

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Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

Rawal,

Kumar,

Sidpara

et al. 2023

J. Micromech. Microeng.

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Micro milling offers the best way to create micro channels; however, the burr formation and surface roughness of the micro channel are difficult to control. Micro channel fabrication and their characterization of stir cast Al6061 are rarely investigated. In the present study, Al6061 alloy was processed by the bottom pouring stir casting method. The micro channels were fabricated on a base and stir cast Al6061 alloys using TiSIN-coated micro end mill tools. The influence of micromachining parameters such as spindle speed, feed rate, and depth of cut on burr formation, cutting force, burr size, and surface roughness was investigated. A comparison was made between the findings obtained from the micro milling of the base and stir cast Al6061 alloys. The surface morphology of fabricated micro channels was analysed and correlated with the roughness profile to understand the channel profile and burr formation. The top burr formation mechanism in stir cast Al6061 alloy was investigated in detail. Low feed rate, low depth of cut, and high spindle speed produced the micro channel with fewer burrs, low surface roughness, and low cutting forces. At the optimum parameter, stir cast Al6061 alloy showed an approximate 420%, 16%, and 300% increase in Fy, Fz, and Ra, respectively, as compared to the base Al6061 alloy. Adhesion wear, built-up edge, and microchipping were found to be the main tool wear mechanisms in micro machining of stir cast alloy. This study directs the choice of cutting parameters for the stir cast micro milling process.

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Section: Morphological and Topographical Analyses Of Micro Channelssupporting

confidence: 56%

Section: Analysis Of Burr Formation Mechanismmentioning

confidence: 99%

Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

Rawal,

Kumar,

Sidpara

et al. 2023

J. Micromech. Microeng.

View full text Add to dashboard Cite

show abstract

“…In the machining process of mechanical components, it is inevitable to generate defects, such as burrs and flash, which occur at the edge positions of the components, and this is particularly true for small components like aerospace nozzles, blade micro-holes, and additive manufacturing parts [1]. These defects significantly compromise the assembly accuracy and reliability of the machine.…”

Section: Introductionmentioning

confidence: 99%

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

Zou,

Ying,

et al. 2024

Surf. Sci. Tech.

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Magnetic needle grinding processing technology is one of the magnetic grinding processing techniques. It possesses the characteristics of micro-cutting removal, small increase in processing temperature, flexible processing, high-quality, and high-precision processing. It is mainly utilized to remove burrs at the edge of the workpiece and the edge of the hole, as well as to finish the surface of the workpiece. It is frequently employed in civil, aerospace, navigation, and other fields. Due to the randomness and complexity of magnetic needle movement in magnetic abrasive finishing, it is difficult to quantify the processing parameters and predict processing effects. Therefore, this paper establishes a simulation model of magnetic needle in magnetic abrasive finishing by the coupling numerical simulation method of fluid dynamics discrete element method (CFD-DEM) to analyze the working state parameters of the magnetic needle. Through the simulation of actual working conditions, the machining process and parameters of magnetic abrasive finishing are quantified and analyzed, and the motion trend of magnetic needles during the machining process is studied. Then, the residual stress of single magnetic needle impact is analyzed with ABAQUS, and the performance enhancement of the workpiece is predicted. Finally, observations of surface morphology and validation of residual stress prediction were conducted through experiments on an aluminum plate. The results show that the residual stress of the aluminum plate is positively correlated with the number of strikes of the magnetic needle. The residual stress changes from tensile stress (+0.1 MPa) to compressive stress (-16.5 MPa). The comparison between simulation results and experimental results is good, indicating that the simulation model can comprehensively consider multiple factors such as magnetic field, particle motion, and fluid flow, and establish a magnetic needle magnetic grinding process model that is suitable for actual working conditions.

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3D surface topography analysis and functionality-related performance of the machined surface in slot micro-milling titanium alloy Ti6Al4V

Zhang

Bai

Wang

2023

Int J Adv Manuf Technol

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Burr formation mechanism and machining parameter effect in slot micro-milling titanium alloy Ti6Al4V

Cited by 12 publications

References 41 publications

Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

3D surface topography analysis and functionality-related performance of the machined surface in slot micro-milling titanium alloy Ti6Al4V

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