Micromilling of metallic materials

Takács, Márton; Verő, Balázs; Mészarós, István

doi:10.1016/s0924-0136(03)00064-5

Cited by 72 publications

(45 citation statements)

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“…The hard reinforcements which are separated from the substrate slide over the cutting edge during machining, consequently contribute to the amount of tool wear [16]. The tool wear modes affecting the machining performance can be generally classified as abrasive wear, chipping on the cutting edge, fractures and fatigue as a result of both thermal and mechanical load [16,17]. In conventional machining, a lot of studies regarding the tool wear modes and mechanism during the process of MMCs materials can be found.…”

Section: State-of-the-art Shaping Processes For Mmcs and Tool Wear Ismentioning

confidence: 99%

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Teng

Huo

Wong

et al. 2016

Int J Adv Manuf Technol

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As a composite material with combination of low weight and high engineering strength, metal matrix composites (MMCs) have been utilised in numerous applications such as aerospace, automobile, and bioengineering. However, MMCs are recognised as difficult-to-cut materials due to their improved strength and high hardness of the reinforcing particles. This paper presents an experimental investigation on micro-machinability of Mg-based MMCs reinforced with Ti and TiB 2 nano-sized particles. The tool wear of AlTiN-coated micro-end mills was investigated. Both abrasive and chip adhesion effect were observed on the main cutting edges, whilst the reinforcement materials and volume fraction play an important role in determining the wear type and severity. The influence of cutting parameters on the surface morphology and cutting force was studied. According to analysis of variance (ANOVA), depth of cut and spindle speed have significant effect on the surface roughness. The specific cutting energy, surface morphology and the minimum chip thickness was obtained and characterised with the aim of examining the size effect. Furthermore, higher cutting force and worse machined surface quality were obtained at the small feed per tooth ranging from 0.15 to 0.5 μm/tooth indicating a strong size effect. Overall, Mg/TiB 2 MMCs exhibit better machinability.

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Section: State-of-the-art Shaping Processes For Mmcs and Tool Wear Ismentioning

confidence: 99%

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Teng

Huo

Wong

et al. 2016

Int J Adv Manuf Technol

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“…The results indicated that the surface generation mechanism at these speeds included not only geometric considerations, but also the minimum chip thickness, ploughing, and elastic recovery effects. Takacs et al (2003) found the harder the material, the better the surface quality. Further it was discovered the lifetime of the tool was longer if the material was more ductile.…”

Section: Surface Roughness Problemmentioning

confidence: 98%

Surface generation analysis in micro end-milling considering the influences of grain

et al. 2007

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The micro end-milling method is a universal micro manufacturing method used to fabricate micro parts and complex 3D micro structures with many materials. Although micrometer size is achieved, their surface quality is not satisfactory. In this paper, the influences of different metal phase grains are researched, and the micro endmilling process is described considering the workpiece with anisotropic properties in micro scope. In this research, the physical characteristics of different grains, specifically friction coefficient l and elastic modulus E, are very critical to determine the processes of the chip formation and the surface generation. And the chips are often discontinuous because of the grain boundary effect. Through the micro end-milling experiment, the results of bottom surface correlate very well with the theoretical analysis.

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“…The main problem encountered is poor tool performance in terms of low stiffness and edge strength causing premature breakage, severe wear, and short tool life [3][4][5][6][7][8][9]. As a result, the quality of the machined workpiece cannot match the required specifications in applications [2,[9][10][11][12][13][14][15]. Some researchers stated that micro cutting tools have become the bottleneck of the micromilling technology [16,17].…”

Section: Introductionmentioning

confidence: 99%

“…When machining low strength materials, the observed dominant tool wear types were flank wear and crater wear, and the cutting tools worn out slowly [4,7,8]. In milling high strength materials, micro tools mainly suffered from chipping off at the cutting edge corners resulting in high wear rates [3,4,10] or premature breakage. This indicates that the geometry of micro endmills should be designed and chosen depending on the type of applications.…”

Section: Introductionmentioning

confidence: 99%

Design of micro square endmills for hard milling applications

Oosterling

Hoogstrate

et al. 2011

Int J Adv Manuf Technol

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In experiments of machining hardened tool steels (such as AISI H11, H13, and D2, up to 56 HRC) by commercial Ø 0.5 mm square endmills, it is observed that the tested micro endmills showed severe wear at an early stage of the process due to chipping off around cutting edge corners, resulting in unsatisfactory tool life and product appearance (burr formation). Detailed examination of current tool geometry shows that it is mainly inherited from that of macro endmills, making the cutting edge corners the weakest part on the tool. As the micromilling process is characterized by small values of machining parameters, the cutting edge corners of the micro endmill are the most loaded part of the cutting edges. New design rules are studied for improving the stiffness and strength of micro endmills used in micro hard milling applications. Analytical modelling and finite element method analysis are used to aid the design of tool geometry. By using a larger neck angle, optimizing tool core geometry, and choosing a negative rake angle, tool stiffness and cutting edge strength are improved. The new endmill designs, both two-flute and four-flute, are tested in experiments on hardened tool steels and showed considerable lower tool wear and increased tool life. Furthermore, the geometrical accuracy and appearance of the workpiece (burr formation) has been improved drastically.

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Micromilling of metallic materials

Cited by 72 publications

References 0 publications

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Micro-machinability of nanoparticle-reinforced Mg-based MMCs: an experimental investigation

Surface generation analysis in micro end-milling considering the influences of grain

Design of micro square endmills for hard milling applications

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