Cutting surface quality analysis in micro ball end-milling of KDP crystal considering size effect and minimum undeformed chip thickness

Chen, Ni; Chen, Mingjun; Wu, Congcong; Pei, Xudong

doi:10.1016/j.precisioneng.2017.06.015

Cited by 34 publications

(20 citation statements)

References 21 publications

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“…The characteristic frequencies of three-dimensional cutting forces should be an integral multiple of the fundamental frequency of 1000 Hz [ 22 ], however, the characteristic frequencies of 430, 510, 1430 and 1510 Hz are appeared in the cutting force which may be caused mainly by the minimum cutting thickness effect [ 21 ]. As shown in reference [ 14 ], the minimum value for maximum undeformed chip thickness in one cutting circle to form the chips is more likely between 238.9 and 339.9 nm in micro ball end milling of KDP crystal and the feed per tooth is between 1.16 μm/z and 1.66 μm/z under the depth of cut of 2 μm. In this work, the feed per tooth of 1 μm/z is set, therefore the chips are formed under one or two tool passes.…”

Section: Resultsmentioning

confidence: 99%

“…For these three depth of cut, the static component of the cross feed force decreases with the increase of spindle speed from 10,000 to 70,000 r/min. The reason is that thermal softening effect is more dominated that strain-hardening effect leading to the increase of the ductility with the increase of spindle speed in micro ball end-milling of KDP crystal [ 14 ]. Relatively speaking, the static component of the cross feed force decreases sharply with the spindle speed increasing from 10,000 to 40,000 r/min, this is mainly caused by the brittle cutting when spindle speed is at a relatively small value.…”

Section: Resultsmentioning

confidence: 99%

“…The roughness Ra value on the whole machined surface which is less than 2 nm can be got. Recently, Chen et al [ 13 , 14 ] revealed that the surface quality is closely related with the cutting parameters and the surface roughness value Ra of machined grooves could be controlled below 20 nm by optimizing the cutting parameters both in micro milling of KDP crystal.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, many researchers discovered that size effect, which is manifested as ploughing effect is appeared usually in micro machining of metals [ 15 , 16 ] and several researchers (like Arif et al [ 17 ] and Amin et al [ 18 ]) found size effect in end-milling of brittle materials. In particular, Chen et al [ 14 ] found that size effect which is manifested as severe ploughing and rubbing effect is appeared when the undeformed chip thickness is smaller than a certain value in micro milling of KDP crystal. However, the above researchers mainly studied how cutting parameters influences the machined surface roughness and few researchers studied which factors got easily in online machining would be used to monitor the machined surface roughness in micro machining of KDP crystal.…”

Section: Introductionmentioning

confidence: 99%

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Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal

Chen

et al. 2018

Micromachines

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Potassium dihydrogen phosphate (KDP or KH2PO4) crystal is widely used as terminal frequency converters in inertial confinement fusion (ICF). However, KDP crystal is a typical difficult-to-cut optical crystal with the characteristic of soft-brittle. In this work, the relationship between cutting force and processed surface quality in micro ball end-milling of KDP crystal with various depth of cut and spindle speed is studied by carried out the micro-milling experiments. Fast Fourier Transform (FFT) algorithm is used to diagnose the recorded cutting force. The periodic change of cutting force and the cutting force after filtering noises can be got through FFT analysis. Through calculating the correlation coefficients between the static component of thrust force and roughness value Ra of machined grooves, as well as the peak-valley (P-V) value of thrust force and dimensional error of machined grooves, the roughness value Ra and dimensional error of machined grooves would be predicted by monitoring the static component and P-V value of the thrust force, respectively. The relatively large spindle speed helps to reduce the roughness value Ra. The spindle speed with moderate value is recommended to reduce the dimensional error of machined groove because the dimensional error of machined groove will increase when the spindle speed is small enough (causing brittle cutting) or large enough (reducing cutting stability).

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal

Chen

et al. 2018

Micromachines

Self Cite

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“…The results showed that the deformation coefficient of chip thickness and specific cutting energy increases with the ratio of uncut chip thickness to cutting edge radius decreasing due to the extruding of the round cutting edge. Chen et al [10] analyzed the cutting surface quality in microball end milling considering size effect. The authors concluded that the surface roughness Ra decreases with the increasing of depth of cut for size effect points.…”

Section: Introductionmentioning

confidence: 99%

Forces prediction in micro-grinding single-crystal copper considering the crystallographic orientation

Zhao

et al. 2018

Manufacturing Rev.

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In the micro-grinding of single-crystal copper, the effect of crystallography becomes significant as the wheel works intra-crystalline. To quantify the effect of crystallographic orientation (CO) related to the cutting direction on the micro-grinding process, this article presents a Taylor factor model by examining the number and style of activated slip systems. Then, the flow stress model of monocrystalline material is developed considering the variation of the Taylor factor. Furthermore, the models of chip formation and rubbing forces are derived from the flow stress model, while the plowing force is predicted by the Vickers hardness. Then, the overall grinding force model of the whole wheel is developed by incorporating the process parameters and the wheel properties. Finally, micro-grinding experiments are conducted to verify the model, using only the Taylor factor as the variable. The proposed analysis is also compared with the previously reported model, which considers the Taylor factor as a constant of 3.06. The comparison between the two predictions and experimental data shows that the consideration of Taylor factor variability improves the accuracy of prediction.

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Study on the burr formation process in micro-milling of high aspect ratio structures

Zhang

Chen

et al. 2021

Int J Adv Manuf Technol

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High-aspect-ratio (HAR) micro-structures of harden steel (SKD11) are widely used in the national defense and electronic elds. Micro-milling is a suitable method for machining HAR micro structures, however the inevitable generation of burrs deteriorates the machined surface. Previous studies have mostly focused on the burr formation process of shallow grooves, but have ignored HAR grooves. This paper investigated the burr formation mechanism in HAR (2:1) grooves on harden steel (SKD11). Due to the fact that the burr formation process was di cult to be observed in the actual micro-milling process, a nite element model was established. A corresponding experimental research was conducted, which revealed a good consistency between simulation and experimental results. Moreover, a new burr type was formed on the sidewall of the HAR groove, which was transformed from top burrs and was named as side burr. The results demonstrated that the chip ow on the rake face of the micro-mill was hindered by the sidewall, which caused chip crumbling, chip accumulation, and surface scraping, seriously affecting the burr formation mechanism. This paper revealed the burr formation mechanism for HAR grooves, and provided research direction for improving the machining accuracy of HAR grooves.

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Cutting surface quality analysis in micro ball end-milling of KDP crystal considering size effect and minimum undeformed chip thickness

Cited by 34 publications

References 21 publications

Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal

Research on the Relationship between Cutting Force and Machined Surface Quality in Micro Ball End-Milling of Potassium Dihydrogen Phosphate Crystal

Forces prediction in micro-grinding single-crystal copper considering the crystallographic orientation

Study on the burr formation process in micro-milling of high aspect ratio structures

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