Fabrication of large aspect ratio (LAR) PCD micro-end mill with a hybrid method and performance verification

Han, Jinjin; Hao, Xiaohong; Li, Liang; He, Ning; Zhao, Guolong; Chen, Ni

doi:10.1007/s00170-019-04047-9

Cited by 10 publications

(3 citation statements)

References 30 publications

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“…To achieve micro-grooves with superior machined quality, a series of parametric experiments were carried out to investigate the effects of cutting parameters on surface roughness ( R a ) first. According to the previous research results and experiences, 22 the spindle speed ( n ) was kept as a constant. The input variables were feed per tooth ( f z ) and depth of cut ( a p ), and six levels and four levels were set, respectively.…”

Section: Experimental Setup and Methodologymentioning

confidence: 99%

Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring

Yang

Han

Hao

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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High aspect ratio micro-grooves are critical structures in the micro-electromechanical system. However, problems like rapid tool wear, low processing efficiency, and inferior machined quality in micro-milling of high aspect ratio micro-grooves by length–diameter ratio tools are particularly significant. In this work, a combined micro-milling method based on water-free alcohol as the cutting fluid and laser deburring is proposed to investigate the high aspect ratio micro-groove generation of oxygen-free high-conductivity copper TU1. Parametric experiments and high aspect ratio micro-groove experiments were conducted to investigate the surface quality, cutting forces, and tool wear. The water-free alcohol was employed to improve the tool life and machined surface quality. In the case of the oxygen-free high-conductivity copper TU1 material, a satisfactory high aspect ratio micro-groove (groove-width = 0.2 μm and aspect ratio = 2.5) with a nanoscale surface roughness ( Ra = 68 nm) was obtained under the preferred machining conditions. Furthermore, the deburring process of the high aspect ratio micro-groove by the laser technology was conducted to achieve ideal machined quality of the top surfaces.

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Section: Experimental Setup and Methodologymentioning

confidence: 99%

Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring

Yang

Han

Hao

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

Self Cite

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show abstract

“…Considering above shortcomings and the structural characteristics of the developed LAR PCD cutters, an improved technological process of the alternate mode of the laser forming and precision grinding was proposed, and more details can be found in Ref. [27]. This alternative mode could effectively avoid tool breakage and reduce machining defects.…”

Section: Design Of Lar Pcd Micromilling Cuttermentioning

confidence: 99%

“…Most importantly, the machined quality of LAR PCD cutters is significantly improved. For the preparation process, the laser parameters used were laser power P = 15 W, scanning speed V = 0.5 mm/s, and defocusing amount D a = 0 µm [27]. The grinding conditions utilized were the wheel speed of 19.63 m/s and the workpiece infeed speed of 0.25 mm/min [28].…”

Section: Design Of Lar Pcd Micromilling Cuttermentioning

confidence: 99%

Experimental Research on Deep-And-Narrow Micromilled Grooves Using a Self-Fabricated PCD Micro-Cutter

Han

Hao

et al. 2021

Micromachines

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Deep-and-narrow micro-grooves are the common functional structures of miniature parts. The fabrication of the micromilled grooves with high quality and accuracy is the essential guarantee of the causative performance for these miniature parts, and micromilling is the most versatile process to machine such micro-grooves. However, micromilling technology is a highly tool-dependent process, and the commercial carbide micromilling cutter has shown obvious deficiencies in terms of rapid tool wear and inferior machined quality during the machining process. In this paper, a polycrystalline diamond (PCD) micromilling cutter with a large-aspect-ratio (LAR) was designed and prepared by the self-proposed hybrid fabrication method of laser and precision grinding. Micromilling experiments on oxygen-free copper were conducted, and the carbide micromilling cutter was selected in the comparative experiments. The variations of milling forces and specific energy were analyzed through the parameter experiments. Then, the surface quality, machined accuracy and tool wear were further investigated. Results showed that the PCD micromilling cutter with an aspect ratio of 3.25 was successfully manufactured by the proposed hybrid method. The self-fabricated PCD micromilling cutter presented remarkable superiority in terms of the surface quality, machined accuracy, and tool wear when preparing deep-and-narrow micro-grooves. Finally, a satisfactory micromilled groove with an aspect ratio of 2.5 was achieved with the self-fabricated LAR PCD cutter under the optimized conditions.

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Suppressing the burr of high aspect ratio structure by optimizing the cutting parameters in the micro-milling process

Chen

Zhang

et al. 2020

Int J Adv Manuf Technol

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Fabrication of large aspect ratio (LAR) PCD micro-end mill with a hybrid method and performance verification

Cited by 10 publications

References 30 publications

Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring

Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring

Experimental Research on Deep-And-Narrow Micromilled Grooves Using a Self-Fabricated PCD Micro-Cutter

Suppressing the burr of high aspect ratio structure by optimizing the cutting parameters in the micro-milling process

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