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“…The main advantage of micromilling process is it capability to fabricate 3D sculptured surfaces with different geometrical complexity and material [37]. Therefore, it is of great importance the study of needle surface integrity and the influence of adding nanoadditives in an oil vegetablebased lubricant.…”
The use of nanoadditives in lubricants has gained much attention to the research community due to the enhancement of tribological properties and cooling capabilities. This paper studies the advantages of using a MQL (Minimum Quantity of Lubrication) system and nanoadditive in the manufacture of microneedle arrays in Ti6Al4V ELI alloy. Tungsten carbide ball nose tools with a cutting diameter of 200 µm were used in experimental tests. Surface and dimensional characterization was performed to evaluate the impact of a nanoadditive to a vegetable-based oil. Additionally, cutting forces and cutting edge radius (CER) were measured while needles were machined. Experimental tests confirmed that micro end milling with nanoadditives provide slightly better dimensional features and low cutting forces compared to oil. The performance of nanoadditives resulted in a reduction of surface roughness (~ 0.3 μm). Qualitative study of microneedles illustrated burr formation on needle surface manufactured without a nanoadditive solution. Results reveal an increment of CER using low feed rate values (2.0 µm/flute) while a reduction of CER was observed with feed rates up to 2.5 µm/flute. Our results indicated that the addition of nanoadditives to vegetable oil promotes a better product surface topography and cutting tool performance.
“…The main advantage of micromilling process is it capability to fabricate 3D sculptured surfaces with different geometrical complexity and material [37]. Therefore, it is of great importance the study of needle surface integrity and the influence of adding nanoadditives in an oil vegetablebased lubricant.…”
The use of nanoadditives in lubricants has gained much attention to the research community due to the enhancement of tribological properties and cooling capabilities. This paper studies the advantages of using a MQL (Minimum Quantity of Lubrication) system and nanoadditive in the manufacture of microneedle arrays in Ti6Al4V ELI alloy. Tungsten carbide ball nose tools with a cutting diameter of 200 µm were used in experimental tests. Surface and dimensional characterization was performed to evaluate the impact of a nanoadditive to a vegetable-based oil. Additionally, cutting forces and cutting edge radius (CER) were measured while needles were machined. Experimental tests confirmed that micro end milling with nanoadditives provide slightly better dimensional features and low cutting forces compared to oil. The performance of nanoadditives resulted in a reduction of surface roughness (~ 0.3 μm). Qualitative study of microneedles illustrated burr formation on needle surface manufactured without a nanoadditive solution. Results reveal an increment of CER using low feed rate values (2.0 µm/flute) while a reduction of CER was observed with feed rates up to 2.5 µm/flute. Our results indicated that the addition of nanoadditives to vegetable oil promotes a better product surface topography and cutting tool performance.
“… Fig. 1 Chip formation mechanism of a macro-milling and b micro-milling in terms of minimum undeformed chip thickness h min and cutting edge radius r e (Adapted and reprinted from “Machining scale: workpiece grain size and surface integrity in micro end milling” by Rodrigues and Jasinevicius [ 28 ], with permission from Elsevier) …”
Micro-milling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy, and efficiency in a wide range of materials. In particular, the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain, as well as for rapid micro-texturing and micro-patterning, which will have great importance in the near future in bio-implant manufacturing. This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries. However, inherent physical process constraints of machining arise as macro-milling is scaled down to the microdomain. This leads to some physical phenomena during micro-milling such as chip formation, size effect, and process instabilities. These dynamic physical process phenomena are introduced and discussed in detail. It is important to remember that these phenomena have multifactor effects during micro-milling, which must be taken into consideration to maximize the performance of the process. The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved. Additionally, newly developed processes that combine conventional micro-milling with other technologies, which have great prospects in reducing the issues related to the physical process phenomena, are also introduced. Finally, the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.
“…7). A coarser microstructure is accompanied with a higher ductility and thus a larger possible plastic deformation of the material during machining [47], as larger grains facilitate the dislocation movement [53] on which the plastic deformation of metals is based. In general, the amount of plastic deformation of the material in the cutting zone is the decisive factor for the burr formation.…”
Section: Burrsmentioning
confidence: 99%
“…In general, the amount of plastic deformation of the material in the cutting zone is the decisive factor for the burr formation. A more intense dislocation movement and thus a greater plastic deformation favors burr formation [47,53]. The dislocation movement in the reference material is more pronounced in comparison to the L-PBF material due to its coarser microstructure.…”
Laser-based powder bed fusion (L-PBF) is a promising technology for the production of near net–shaped metallic components. The high surface roughness and the comparatively low-dimensional accuracy of such components, however, usually require a finishing by a subtractive process such as milling or grinding in order to meet the requirements of the application. Materials manufactured via L-PBF are characterized by a unique microstructure and anisotropic material properties. These specific properties could also affect the subtractive processes themselves. In this paper, the effect of L-PBF on the machinability of the aluminum alloy AlSi10Mg is explored when milling. The chips, the process forces, the surface morphology, the microhardness, and the burr formation are analyzed in dependence on the manufacturing parameter settings used for L-PBF and the direction of feed motion of the end mill relative to the build-up direction of the parts. The results are compared with a conventionally cast AlSi10Mg. The analysis shows that L-PBF influences the machinability. Differences between the reference and the L-PBF AlSi10Mg were observed in the chip form, the process forces, the surface morphology, and the burr formation. The initial manufacturing method of the part thus needs to be considered during the design of the finishing process to achieve suitable results.
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