Design and fabrication of a new micro ball-end mill with conical flank face

Liang, Zhiqiang; Li, Shidi; Zhou, Tianfeng; Gao, Peng; Zhang, Dongdong; Wang, Xibin

doi:10.1007/s00170-018-1924-y

Cited by 9 publications

(2 citation statements)

References 16 publications

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“…This fabrication process also has the potential to fabricate tools with different helix angle as well as other shapes like dovetail profile or ball end mills. Liang et al [163] have used a six axis CNC grinding machine to produce micro conical surface ball-end mills (CSBM) with 500 μm diameter and normal rake and relief angle of 10°and 20°, respectively. In their study, the kinematic principle of the six axis CNC grinding machine has been used to realize micro ball end mills with a diameter error of about 0.26%.…”

Section: Tablementioning

confidence: 99%

Micro tool design and fabrication: A review

Oliaei

Karpat

Davim

et al. 2018

Journal of Manufacturing Processes

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Mechanical micromachining is considered as a cost-effective and efficient fabrication technique to produce three dimensional features and free-form surfaces from various engineering materials. Micro cutting tools are an essential part of mechanical micromachining and they are exposed to harsh conditions which reduces tool life and adversely affect the economics of the process. The challenge is therefore to maintain the tool rigidity and cutting edge sharpness for extended period of time. Thus, the design, fabrication and durability of micro cutting tools are of significant importance for successful micromachining operations. This review paper aims to provide a comprehensive understanding about the capabilities, characteristics, and limitations of different fabrication techniques used in the manufacturing of micro cutting tools. State-of-the-art micro cutting tool design and coating technology has been presented for various micromachining applications. Possible future research direction and development in the field of micro tool design and fabrication has also been discussed.

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Section: Tablementioning

confidence: 99%

Micro tool design and fabrication: A review

Oliaei

Karpat

Davim

et al. 2018

Journal of Manufacturing Processes

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“…It is also usually accompanied by a rapid/sharp increase in specific cutting forces, particularly as the uncut chip thickness is reduced, which can lead to detrimental workpiece surface integrity [ 12 ]. Furthermore, arbitrarily increasing the uncut chip thickness to improve cutting efficiency during micromilling is often not feasible, as the risk of higher cutting loads can easily lead to catastrophic edge fracture or tool breakage [ 13 ]. Therefore, understanding the incidence of the size effect is essential for selecting appropriate cutting conditions as well as for optimising micromachining operations.…”

Section: Introductionmentioning

confidence: 99%

Influence of Size Effect in Milling of a Single-Crystal Nickel-Based Superalloy

et al. 2023

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This paper details an experimental investigation on the influence of the size effect when slot-milling a CMSX-4 single-crystal nickel-based superalloy using 1 mm- and 4 mm-diameter TiAlN-coated tungsten carbide (WC) end-mills. With all tools having similar cutting-edge radii (re) of ~6 µm, the feed rate was varied between 25–250 mm/min while the cutting speed and axial depth of cut were kept constant at 126 m/min and 100 µm, respectively. Tests involving the Ø 4 mm end-mills exhibited a considerable elevation in specific cutting forces exceeding 500 GPa, as well as irregular chip morphology and a significant increase in burr size, when operating at the lowest feed rate of 25 mm/min. Correspondingly for the Ø 1 mm micro-end-mills, high levels of specific cutting forces up to ⁓1000 GPa together with severe material ploughing and grooving at the base of the machined slots were observed. This suggests the prevalence of the size effect in the chip formation mechanism as feed per tooth/uncut chip thickness decreases. The minimum uncut chip thickness (hmin) when micromilling was subsequently estimated to be less than 0.10 re, while this increased to between 0.10–0.42 re when machining with the larger Ø 4 mm tools.

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Fabrication of large aspect ratio (LAR) PCD micro-end mill with a hybrid method and performance verification

Han

Hao

et al. 2019

Int J Adv Manuf Technol

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Design and fabrication of a new micro ball-end mill with conical flank face

Cited by 9 publications

References 16 publications

Micro tool design and fabrication: A review

Micro tool design and fabrication: A review

Influence of Size Effect in Milling of a Single-Crystal Nickel-Based Superalloy

Fabrication of large aspect ratio (LAR) PCD micro-end mill with a hybrid method and performance verification

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