Development of vibration-assisted micro-milling device and effect of vibration parameters on surface quality and exit-burr

Li, Guo; Wang, Bo; Xue, Jiadai; Qu, Da; Zhang, Peng

doi:10.1177/0954405418774592

Cited by 16 publications

(14 citation statements)

References 25 publications

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“…Further work is necessary to optimize even this basic unidirectional vibration-assisted micro-milling process. Li et al [ 54 ] provided some of this developmental work also in the feed direction. They determined that larger vibration amplitudes actually increased the exit burr size.…”

Section: Fundamentals Of the Processmentioning

confidence: 99%

Precision micro-milling process: state of the art

2020

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Micro-milling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy, and efficiency in a wide range of materials. In particular, the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain, as well as for rapid micro-texturing and micro-patterning, which will have great importance in the near future in bio-implant manufacturing. This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries. However, inherent physical process constraints of machining arise as macro-milling is scaled down to the microdomain. This leads to some physical phenomena during micro-milling such as chip formation, size effect, and process instabilities. These dynamic physical process phenomena are introduced and discussed in detail. It is important to remember that these phenomena have multifactor effects during micro-milling, which must be taken into consideration to maximize the performance of the process. The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved. Additionally, newly developed processes that combine conventional micro-milling with other technologies, which have great prospects in reducing the issues related to the physical process phenomena, are also introduced. Finally, the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.

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Section: Fundamentals Of the Processmentioning

confidence: 99%

Precision micro-milling process: state of the art

2020

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“…x e c (z c , h), y e c (z c , h), and z e c (z c , h) are the components of the P e (z, h). That means when the edge is on the ellipse, the point satisfies equation 4and equation (13). Then, the following equation is derived…”

Section: The Accurate Model For Iuctmentioning

confidence: 99%

“…In order to solve these difficulties, many researchers have studied these issues. Li et al 13 develop a vibration-assisted micro-milling device and study effect of vibration parameters on surface quality. Kim et al 14 use a static IUCT model combining the minimum chip thickness.…”

Section: Introductionmentioning

confidence: 99%

An accurate instantaneous uncut chip thickness model combining runout effect in micro-milling using cutters with the non-uniform helix and pitch angles

Guo

Jiang

Yang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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As a key factor, the accuracy of the instantaneous undeformed thickness model determines the force-predicting precision and further affects workpiece machining precision in the micro-milling process. The runout with five parameters affects the machining process more significantly compared with macro-milling. Furthermore, modern industry uses cutters with non-uniform pitch and helix angles more and more common for their excellent properties. In this article, an instantaneous undeformed thickness model is presented regarding cutter runout, variable pitch, and helix angles in the micro-milling process. The cutter edge with the cutter runout effect is modeled. Then, the intersecting ellipse between the plane vertical to the spindle axis and the cutter surface which is a cylinder can be gained. Based on this, the points, which are used to remove the material, on the ellipse as well as cutter edges are calculated. The true trochoid trajectory for each cutting point along the tool path is built. Finally, the instantaneous undeformed thickness values are computed using a numerical algorithm. In addition, this article analyzes runout parameters’ effects on the instantaneous undeformed thickness values. After that, helix and pitch angles’ effects on the instantaneous undeformed thickness are studied. Ultimately, the last section verifies the correctness and validity of the instantaneous undeformed thickness model based on the experiment conducted in the literature.

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“…36 Vibration-assisted micro-milling setup based on piezoelectric plates was used to characterize the exit burr size. 37 The status and advancement of characterization, modeling, and control of burr formation have been reviewed. They summarized that the cutting parameters, workpiece mechanical properties, tool geometry, coating, and cutting fluids are such factors that affect the burr formation in micro-milling operations.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of top burr formation in high-speed micro-milling of Ti6Al4V alloy

Kumar

Bajpai

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Miniaturization with superior quality product of super alloy is the demand of the industry. Ti6Al4V is the demanding super alloy due to its excellent material properties, although this super alloy is known for poor machinability in terms of burr formation, low tool life, and poor surface finish. Therefore, being a popular super alloy, it comes under the difficult-to-cut material. In the current work, burr formation on the machining of Ti6Al4V has been studied. Experimental investigation and characterizations of top burr formation on Ti6Al4V alloy using end milling process were carried out. A scanning electron microscopy identifies the burr formed on the machined surface. A new technique has been introduced to measure the top burr width (i.e. equivalent width) accurately. Equivalent burr width calculated as the ratio of total area of burr generated to the total height. It was observed that equivalent burr width in up milling was increased by 120%, while in down milling, it was decreased by 50% as the speed varies from conventional to high speed. Furthermore, the effects of different cutting parameters and tool parameters on top burr formation have been analyzed to establish correlation among them.

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Development of vibration-assisted micro-milling device and effect of vibration parameters on surface quality and exit-burr

Cited by 16 publications

References 25 publications

Precision micro-milling process: state of the art

Precision micro-milling process: state of the art

An accurate instantaneous uncut chip thickness model combining runout effect in micro-milling using cutters with the non-uniform helix and pitch angles

Experimental investigation of top burr formation in high-speed micro-milling of Ti6Al4V alloy

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