Effect of plastic side flow on surface roughness in micro-turning process

Li, Kai; Melkote, Shreyes N.

doi:10.1016/j.ijmachtools.2005.11.014

Cited by 155 publications

(72 citation statements)

References 23 publications

(33 reference statements)

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“…In secondary edge studies, researchers [1,4,[8][9][10][11][12][13][14][15][16], machining ferrous and non-ferrous work materials with carbide, ceramic (PCD and PCBN) and single crystal diamond (SCD) tool inserts, report peak-to-valley roughnesses, e.g. R z , close to kinematic values f 2 / (8r n ) at large feeds, where f is feed, r n is tool nose radius.…”

Section: Introductionmentioning

confidence: 99%

The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

Childs

Dornfeld

Lee

et al. 2008

CIRP Journal of Manufacturing Science and Technology

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Section: Introductionmentioning

confidence: 99%

The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

Childs

Dornfeld

Lee

et al. 2008

CIRP Journal of Manufacturing Science and Technology

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“…A summary of similar related work with different outcomes is shown in Table 2 to highlight that much of the previous research work attempted to relate surface damage to key machining parameters such as depth of cut, cutting speed and feed rate as well as tool geometry such as the rake angle and tool nose radius [25,[27][28][29]. Indeed the state-of-the-art currently assumes that these parameters are the only variables that can be optimised in order to improve machining performance and, subsequently, the machined surface roughness.…”

Section: Generalmentioning

confidence: 99%

Advances in the surface defect machining (SDM) of hard steels

Rashid

Goel²

2016

Journal of Manufacturing Processes

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Abstract:This paper reports the realisation of precision surface finish (Ra 30 nm) on AISI 4340 steel using a conventional turret lathe by adapting and incorporating a surface defect machining (SDM) method [Wear, 302, 2013[Wear, 302, (1124[Wear, 302, -1135]. Conventional ways of machining materials are limited by the use of a critical feed rate, experimentally determined as 0.02 mm/rev, beyond which no appreciable improvement in the machined quality of the surface is obtained. However, in this research, the novel application of an SDM method was used to overcome this minimum feed rate limitation ultimately reducing it to 0.005 mm/rev and attaining an average machined surface roughness of 30 nm. From an application point of view, such a smooth finish is well within the values recommended in the ASTM standards for total knee joint prosthesis. Further analysis was done using SEM imaging, white light interferometry and numerical simulations to verify that adapting SDM method provides improved surface integrity by reducing the extent of side flow, microchips and weldments during the hard turning process.

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“…The range of the plastically deformed region is two to ten times the indention radius [20]. Because the trapezoidal cross-sectional shape tip has a smaller contact radius in the YOZ plane as compared to the rectangular cross-sectional shape tip, a smaller region of work-affected area is formed [20][21]. Thus the overlap of the deformed layer can be effectively minimized when using tools with trapezoidal cross-sectional shape tips.…”

Section: Denpendence Of the Shape Transferability On The Tool Geometrymentioning

confidence: 99%

“…Thus the overlap of the deformed layer can be effectively minimized when using tools with trapezoidal cross-sectional shape tips. Moreover, the material side flow made a significant contribution to the formation of the nanostructures [9,21]. As the tool with periodic tip configuration has better central symmetry properties than the tool with non-periodic tips configuration, a uniform material side flow is easily achieved and therefore a smaller critical ratio of L/Wf is required.…”

Section: Denpendence Of the Shape Transferability On The Tool Geometrymentioning

confidence: 99%

“…Thus, it is concluded that the tool geometry of nanoscale multi-tip diamond tools has a significant influence on the quality of machined nanostructures. The tool tip angle can effectively control the material side flow [15,21] and minimize the interactions of deformed layers beneath the tool tips during the machining process. A minimum ratio of L/Wf should be met for the high precision machining of nanostructures based on the MD simulation results discussed above.…”

Section: Denpendence Of the Shape Transferability On The Tool Geometrymentioning

confidence: 99%

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Investigation of the shape transferability of nanoscale multi-tip diamond tools in the diamond turning of nanostructures

Luo

Tong

Liang

2014

Applied Surface Science

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In this paper, the shape transferability of using nanoscale multi-tip diamond tools in the diamond turning for scale-up manufacturing of nanostructures has been demonstrated. Atomistic multi-tip diamond tool models were built with different tool geometries in terms of the difference in the tip cross-sectional shape, tip angle, and the feature of tool tip configuration, to determine their effect on the applied forces and the machined nano-groove geometries. The quality of machined nanostructures was characterized by the thickness of the deformed layers and the dimensional accuracy achieved. Simulation results show that diamond turning using nanoscale multi-tip tools offers tremendously shape transferability in machining nanostructures. Both periodic and non-periodic nano-grooves with different cross-sectional shapes can be successfully fabricated using the multi-tip tools. A hypothesis of minimum designed ratio of tool tip distance to tip base width (L/Wf) of the nanoscale multi-tip diamond tool for the high precision machining of nanostructures was proposed based on the analytical study of the quality of the nanostructures fabricated using different types of the multi-tip tools. Nanometric cutting trials using nanoscale multi-tip diamond tools (different in L/Wf) fabricated by focused ion beam (FIB) were then conducted to verify the hypothesis. The investigations done in this work imply the potential of using the nanoscale multi-tip diamond tool for the deterministic fabrication of period and non-periodic nanostructures, which opens up the feasibility of using the process as a versatile manufacturing technique in nanotechnology.

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Effect of plastic side flow on surface roughness in micro-turning process

Cited by 155 publications

References 23 publications

The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

Advances in the surface defect machining (SDM) of hard steels

Investigation of the shape transferability of nanoscale multi-tip diamond tools in the diamond turning of nanostructures

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