Machined channel quality and tool life using cermet micro-mill in micro-milling aluminum alloy

Li, Shasha; Zou, Bin; Xu, Kaitao; YishunWang,

doi:10.1007/s00170-018-3120-5

Cited by 14 publications

(7 citation statements)

References 22 publications

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“…Under the action of the bearing friction force and the turbine resistance, the rotor shaft was decelerated to stop freely. According to the variation law of the speed and time in the stop deceleration segment, the friction torque T f in the stop deceleration segment was calculated using formula (4). The total turbine torque T t was calculated in the starting acceleration segment, and then, the spindle torque was calculated.…”

Section: Experimental Methodsmentioning

confidence: 99%

“…1–3 As a key component in micro-cutting technology, a micro-spindle should not only ensure a high rotation speed and high turning accuracy but also have a compact structure, compact size, and convenient installation. 4–6 Because of their advantages such as easy to realize high speed, no heating during operation, compact structure, and high power density and durability, air turbines have been widely used in micro-spindles, and researchers have carried out a number of relevant studies.…”

Section: Introductionmentioning

confidence: 99%

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Research on aerodynamic characteristics of two-stage axial micro air turbine spindle for small parts machining

Jiang

Guo

Shujing

et al. 2020

Advances in Mechanical Engineering

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In order to meet the requirements of output torque, efficiency and compact shape of micro-spindles for small parts machining, a two-stage axial micro air turbine spindle with an axial inlet and outlet is proposed. Based on the k-ω turbulence model of SST, the flow field and operation characteristics of the two-stage axial micro air turbine spindle were studied using computational fluid dynamics (CFD) combined with an experimental study. We obtained the air turbine spindle under different working conditions of the loss and torque characteristics. When the inlet pressure was 300 KPa, the output speed of the two-stage turbine was 100,000 rpm, 9% higher than that of a single-stage turbine output torque. The total torque reached 6.39 N·mm, and the maximum efficiency of the turbine and the spindle were 42.2% and 32.3%, respectively. Through the research on the innovative structure of the two-stage axial micro air turbine spindle, the overall performance of the principle prototype has been significantly improved and the problems of insufficient output torque and low working efficiency in high-speed micro-machining can be solved practically, which laid a solid foundation for improving the machining efficiency of small parts and reducing the size of micro machine tool.

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Section: Experimental Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Research on aerodynamic characteristics of two-stage axial micro air turbine spindle for small parts machining

Jiang

Guo

Shujing

et al. 2020

Advances in Mechanical Engineering

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show abstract

“…[ 7 , 8 , 9 , 10 ]. The conical degree of the tool and the wear of the tool itself can also affect the size of the burr [ 11 , 12 ]. However, the effect is often not ideal.…”

Section: Introductionmentioning

confidence: 99%

Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

et al. 2023

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Due to the strong plasticity of Inconel 718 and the significant size effect of micromachining, a large number of burrs will be produced in traditional processing. The addition of ultrasonic vibration during machining can reduce the burr problem. The mechanism of burr generation in traditional micromilling (TMM) and ultrasonic vibration-assisted micromilling (UVAMM) was analyzed by simulation, and verified by corresponding experiments. It is found that applying high-frequency ultrasonic vibration in the milling feed direction can reduce cutting temperature and cutting force, improve chip breaking ability, and reduce burr formation. When the cutting thickness will reach the minimum cutting thickness hmin, the chip will start to form. When A/ƒz > 1/2, the tracks of the two tool heads start to cut, and the chips are not continuous. Some of the best burr suppression effects were achieved under conditions of low cutting speed (Vc), feed per tooth (ƒz), and large amplitude (A). When A is 6 μm, the size and quantity of burr is the smallest. When ƒz reaches 6 μm, large continuous burrs appear at the top of the groove. The experimental results further confirm the accuracy of the simulation results and provide parameter reference.

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“…Analysis of variance (ANOVA) results showed that a lower surface roughness of 0.15 µm could be achieved with a low feed rate and high spindle speed. Li et al [35] studied the tool life and micro channel quality assessment using a cermet tool. Tool wear, dimensional accuracy, chip morphology, and burr formation were analysed with reference to the cutting parameters.…”

Section: Introductionmentioning

confidence: 99%

Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

Rawal,

Kumar,

Sidpara

et al. 2023

J. Micromech. Microeng.

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Micro milling offers the best way to create micro channels; however, the burr formation and surface roughness of the micro channel are difficult to control. Micro channel fabrication and their characterization of stir cast Al6061 are rarely investigated. In the present study, Al6061 alloy was processed by the bottom pouring stir casting method. The micro channels were fabricated on a base and stir cast Al6061 alloys using TiSIN-coated micro end mill tools. The influence of micromachining parameters such as spindle speed, feed rate, and depth of cut on burr formation, cutting force, burr size, and surface roughness was investigated. A comparison was made between the findings obtained from the micro milling of the base and stir cast Al6061 alloys. The surface morphology of fabricated micro channels was analysed and correlated with the roughness profile to understand the channel profile and burr formation. The top burr formation mechanism in stir cast Al6061 alloy was investigated in detail. Low feed rate, low depth of cut, and high spindle speed produced the micro channel with fewer burrs, low surface roughness, and low cutting forces. At the optimum parameter, stir cast Al6061 alloy showed an approximate 420%, 16%, and 300% increase in Fy, Fz, and Ra, respectively, as compared to the base Al6061 alloy. Adhesion wear, built-up edge, and microchipping were found to be the main tool wear mechanisms in micro machining of stir cast alloy. This study directs the choice of cutting parameters for the stir cast micro milling process.

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Machined channel quality and tool life using cermet micro-mill in micro-milling aluminum alloy

Cited by 14 publications

References 22 publications

Research on aerodynamic characteristics of two-stage axial micro air turbine spindle for small parts machining

Research on aerodynamic characteristics of two-stage axial micro air turbine spindle for small parts machining

Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

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