Evaluation and selection of hard coatings for micro milling of hardened tool steel

Aramcharoen, Ampara; Mativenga, Paul; Yang, Shicai; Cooke, Kevin; Teer, D.G.

doi:10.1016/j.ijmachtools.2008.05.011

Cited by 153 publications

(78 citation statements)

References 29 publications

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“…But every manufacturing process has its own limitations. For example, the conventional micro-milling process using micro-tools are commonly used but the high tooling cost, burr formation, material constraints offered by difficult-to-machine materials, chip adhesion, high thrust forces, heat affected zone and striation marks are the obvious drawbacks of conventional micro-milling and consequently restrict the process for precise micro-featuring especially in hard-to-machine materials such as titanium and nickel alloys [215][216][217][218][219]. Fabrication of micro-channels in Ti-6Al-4V has been realized by Vazquez et al [220] with the help of tungsten carbide micro-tools using CNC machining center.…”

Section: Fabrication Techniquesmentioning

confidence: 99%

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Darwish

Ahmed

Al‐Ahmari

2016

Advanced Structured Materials

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Laser beam machining (LBM) has proven its applications and advantages over almost all the range of engineering materials. It offers its competences from macro machining to micro and nano-machining of simple-to-complex shapes. The flipside of LBM is the existence of universal problems associated with its thermal ablation mechanism. In order to alleviate or reduce the inherent problems of LBM, a massive research has been done during the past decade and in turn build a relatively new route of laser-hybrid processes. The hybrid approaches in laser ablation have demonstrated much improved results in terms of material removal rate, surface integrity, geometrical tolerances, thermal damage, metallurgical alterations and many more. This chapter reviews the research work carried out so far in the area of LBM and its hybrid processes for different materials and shapes.

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Section: Fabrication Techniquesmentioning

confidence: 99%

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Darwish

Ahmed

Al‐Ahmari

2016

Advanced Structured Materials

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“…In the later research [5], the authors demonstrated that TiN, TiCN, TiAlN, CrN and CrTiAlN coatings help reducing cutting edge chipping and the edge radius wear as well as the micro-burr size.…”

Section: Introductionmentioning

confidence: 98%

Micro milling performance assessment of diamond-like carbon coatings on a micro-end mill

Cheng

2013

Proceedings of the Institution of Mechanical Engineers, Part J:

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In micro milling, unpredictable tool life and premature tool failures are the major constraints for its industrial applications, and prolongation of the tool life so as to enhance the tooling performance presents great challenges. Appropriate coating techniques potentially offer a feasible and promising solution. In the research presented, diamond-like carbon (DLC) films are deposited on a Ø500µm diameter tungsten carbide (WC) micro end mill by the plasma enhanced chemical vapor deposition (PE-CVD) process. Coating characterization has been undertaken and the DLC coatings are found in good coverage on the tool except for a slight delaminating on the edge corners. Besides, the surface of the amorphous coatings is much smoother than that of WC. In addition, comprehensive cutting performance of the DLC coated tool in dry slot milling of Al 6061-T6 has been compared with those of uncoated tools in both dry and wet conditions. It is observed that the use of DLC coatings can reduce the cutting forces, lessen the tool wear, improve the surface roughness and minimize the microburr formation as compared to the corresponding performance of an uncoated tool in dry cutting. However, the performance improvement is still unreachable to those resulting from the cutting fluid influence.

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“…In spite of the extended use of micro-milling systems in recent years, the performance of these processes is still specially challenging because of unpredictable tool life of micro end mills, high wear rates and the negative impact of tool wear on dimensional accuracy and surface quality [5]. In practice, essential product attributes in micro machined parts are nano-range surface finish, high dimensional accuracy and minimal burr size.…”

Section: Introductionmentioning

confidence: 99%

“…In fact, tool life and premature failure of micro tools is a major process constraint. Tool wear is critical since it influences component tolerance, quality, production times and costs [5]. As the cutting tool wears out surface quality is affected and thus, a set of cutting parameters may not be appropriate for the entire life of the cutting-tool [8].…”

Section: Introductionmentioning

confidence: 99%

“…As the cutting tool wears out surface quality is affected and thus, a set of cutting parameters may not be appropriate for the entire life of the cutting-tool [8]. Furthermore, in the regime of micro-milling, the ploughing phenomenon prevents to accurately model the process [5]. To deal with this problem, it is necessary to estimate the cutting-tool wear state and its impact on dimensional and surface quality in order to set the most convenient cutting parameters.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Adaptive control optimization in micro-milling of hardened steels—evaluation of optimization approaches

Coppel

Abellán-Nebot

Siller

et al. 2015

Int J Adv Manuf Technol

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Nowadays, the miniaturization of many consumer products is extending the use of micro-milling operations with high quality requirements. However, the impacts of cutting-tool wear on part dimensions, form and surface integrity are not negligible and part quality assurance for a minimum production cost is a challenging task. In fact, industrial practices usually set conservative cutting parameters and early cutting replacement policies in order to minimize the impact of cutting-tool wear on part quality. Although these practices may ensure part integrity, the production cost is far away to be minimized, especially in highly tool-consuming operations like mold and die micromanufacturing. In this paper, an Adaptive Control Optimization (ACO) system is proposed to estimate cutting-tool wear in terms of part quality and adapt the cutting conditions accordingly in order to minimize the production cost, ensuring quality specifications in hardened steel micro-parts. The ACO system is based on: i) a monitoring sensor system composed of a dynamometer; ii) an estimation module with Artificial Neural Networks models; iii) an optimization module with evolutionary optimization algorithms; and iv) a CNC interface module. In order to operate in a nearly real time basis and facilitate the implementation of the ACO system, different evolutionary optimization algorithms are evaluated such as Particle Swarm Optimization (PSO), Genetic Algorithms (GA) and Simulated Annealing (SA) in terms of accuracy, precision and robustness. The results for a given micro-milling operation showed that PSO algorithm performs better than GA and SA algorithms under computing time constraints. Furthermore, the implementation of the final ACO system reported a decrease in the production cost of 12.3% and 29% in comparison with conservative and high production strategies, respectively.

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Evaluation and selection of hard coatings for micro milling of hardened tool steel

Cited by 153 publications

References 29 publications

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Micro milling performance assessment of diamond-like carbon coatings on a micro-end mill

Adaptive control optimization in micro-milling of hardened steels—evaluation of optimization approaches

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