Effect of cutting parameters on chips and burrs formation with traditional micromilling and ultrasonic vibration assisted micromilling

Abstract

In the traditional micromilling(TMM) of Inconel718 alloy, due to the influence of material plas ticity and size effect, relatively large burr will be produced. In order to solve the burr proble m in micromilling, ultrasonic vibration in feed direction is applied to the workpiece to complet e vibration cutting. Combined with trajectory simulation and cutting experiment, the burr forma tion mechanism of TMM and ultrasonic vibration assisted micromilling(UVAMM) was studied.The results show that when the ratio of amplitude(A) to feed per tooth(ƒz) is greater than 0.5, continuous cutting changes to intermittent cutting. Compared with TMM, UVAMM improves ch ip breaking ability, facilitates the propagation of burr crack and effectively inhibits the formatio n of burr. However, due to the influence of cutting edge radius, A/ƒz should be set larger. Wh en the chip breaking condition is reached, the burr shape is usually tearing or flocculent. Unde r the conditions of low speed(n), large ƒz and large A, the burr suppression is more obvious.

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

“…When f z exceeded 5 µm/z, the influence of UVAM on the surface quality was small, as shown in Fig. 25(a) [164], whereas the CM of the workpiece resulted in a poor surface quality within the given range of parameters. It is well known that surface quality can generally be described by surface roughness, as shown in Fig.…”

“…By applying one-dimensional feed longitudinal vibration (workpiece vibration), the influence of cutting parameters on the surface roughness was studied, and the burr suppression effect by changing A was explored. Fang et al [164] used an ultrasonic energy field with f = 32 kHz and A = 3 µm for milling Inconel 718. The influence of f z (2-6 µm/z) on the surface quality and burr of the workpiece under CM and UVAM conditions was studied.…”

Mushroom-mimetic 3D hierarchical architecture-based e-skin with high sensitivity and a wide sensing range for intelligent perception

“…In order to overcome these shortcomings, micromilling has attracted extensive attention due to its simple and efficient machining of complex microgrooves and microholes. [35][36][37] It would be very meaningful to prepare micropatterns with complex hierarchical architecture and interdigital electrodes by micromilling technology.…”

Tribological Effects of Micromilling of Hardened Aisi D2 Steel on Tool Wear and Top Burr Formation

“…Generally, burrs are removed after machining. However, their removal cannot always be performed due to accuracy requirements for the microcomponent, since deburring can induce residual stresses and dimensional changes that affect its functionality [8]. Therefore, strategies must be devised during micromilling to reduce burr formation.…”

“…This material is commonly subjected to quenching and tempering, thus resulting in a microstructure composed of martensite, retained austenite and carbides, which ensures high hardness and wear resistance which is attributed to the presence of chromium carbides in the microstructure of the material [6]. For these reasons, this material is widely used for the production of dies and molds [7,8]. In this context, machining hardened AISI D2 steel can lead to severe wear of the cutting tool and to its premature fracture.…”