Evaluation of Tool Path Strategy and Cooling Condition Effects on the Cutting Force and Surface Quality in Micromilling Operations

Abstract

Abstract:Compared to milling on a macro scale, the micromilling process has several cumbersome points that need to be addressed. Rapid tool wear and fracture, severe burr formation, and poor surface quality are the major problems encountered in the micromilling process. This study aimed to reveal the effect of cutting path strategies on the cutting force and surface quality in the micromilling of a pocket. The hatch zigzag tool path strategy and the contour climb tool path strategy under different cooling conditions (e.g., dry, air blow, and flood coolant) at fixed cutting parameters. The micromilling tests revealed that better results were obtained with the use of the contour tool path strategy in terms of cutting forces (by up to~43% compared to the dry condition) and surface quality (by up to~44% compared to the air blow condition) when compared to the hatch tool path strategy. In addition, the flood coolant reduces the cutting temperature and eliminates chips to significantly enhance the quality of the micro milled surface.

Modelling and Microstructural Aspects of Ultra-Thin Sheet Metal Bundle Cutting

“…The cutting process of metals is the subject of interest of many researchers [1][2][3][4] as well as entrepreneurs and engineers working in the industrial sector. There are many interesting items in the literature regarding mainly machining [5][6][7][8], but much less attention is given to cover mechanical cutting of guillotines [9,10]. Different approaches are used for simulating failure and metal separation [11][12][13].…”

Machinability Study of Developed Composite AA6061-ZrO2 and Analysis of Influence of MQL

“…(2) The highest hardness value was obtained for AA/ZrO2/10% at 200 gf load, and the value was 107 HV. (3) As per the analysis, the most influential factor which affected surface roughness was the rate of flow (D), and its contribution was 43.58% [24]. The most influential factor which affected …”

“…(3) As per the analysis, the most influential factor which affected surface roughness was the rate of flow (D), and its contribution was 43.58% [24]. The most influential factor which affected cutting force was depth of cut (C), and its contribution was 50.45%.…”

Optimization of Effects of Cutting Parameters and Cutting Tool Path by using Grey Based Taguchi Method

“…Experiment was designed using Taguchi technique. This way it has been possible to achieve more comprehensive results with a smaller number of experiments, to reduce time and cost of the study [22][23][24]. As the roughness of the processed surface and the magnitudes of cutting forces are required to be as small as possible in determination of the quality characteristics, the principle of "the smallest is the best" was used for the quality values expected from the experiments.…”