Numerical simulation of chip ploughing volume in micro ball-end mill machining

Luo, Shijun; Bayesteh, Abdolreza; Ko, Junghyuk; Dong, Zuomin; Jun, Martin Byung‐Guk

doi:10.1007/s12541-017-0108-2

Cited by 5 publications

(4 citation statements)

References 8 publications

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“…Thus, the finish depth of cut was 1.4 μm to improve the convex spherical surface shape accuracy. Under the same cutting depth, the smaller the cutting speed, the larger the shear strain ε, and the more likely the plowing phenomenon [ 29 ]. Taking into account the stability of the machine tool and cutting efficiency, the spindle speed n c was chosen to be 1000 rpm, and the unit displacement along the Z-axis was 2 μm.…”

Section: Cutting Experiments For Convex Spherical Blazed Gratingmentioning

confidence: 99%

Ultra-Precision Cutting and Characterization of Reflective Convex Spherical Blazed Grating Elements

Peng

Guan

et al. 2022

Micromachines

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In this work, based on the diffraction principle of reflective blazed grating, the structure size of the convex spherical blazed grating unit is determined, the machining accuracy of the convex spherical blazed grating is formulated, the effects of tool nose radius and Poisson burr on the diffraction efficiency of the convex spherical blazed grating are analyzed, and the performances of cutting convex gratings with microcrystalline aluminum RSA6061 and RSA6061+ chemically plated NiP for two workpiece materials are compared. A convex spherical blazed grating with a radius of curvature R = 41.104 mm, substrate diameter 14 mm, grating density 53.97 line/mm, and blaze angle of roughly 3.8° is turned by a four-axis ultra-precision machining system by adjustment of the cutting tool, workpiece material, and cutting parameters, as well as modification of the layouts of the blazed grating on the convex sphere. The results of the testing of convex spherical blazed grating elements in both layouts show that the size error of the grating period is close for both layouts, the size error of grating height is smaller in the equal-along-arc layout, the blaze angle error in the equal-along-projection layout is only 0.74%, and the average roughness of the blazed surface is less than 5 nm to meet the processing quality requirements of the reflective convex spherical blazed grating. The greater the blaze angle accuracy of the blazed grating, the higher its diffraction efficiency, so the grating element with an equal-along-projection layout has a higher diffraction efficiency than the grating element with an equal-along-arc layout. RSA6061+ chemically plated NiP material is superior to RSA6061 material in Poisson burr height and blazed surface roughness, which is more suitable for Offner-type imaging spectrometers in the spectral range 0.95–2.5 μm (SWIR).

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Section: Cutting Experiments For Convex Spherical Blazed Gratingmentioning

confidence: 99%

Ultra-Precision Cutting and Characterization of Reflective Convex Spherical Blazed Grating Elements

Peng

Guan

et al. 2022

Micromachines

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“…However, as the cutting depth is further reduced, the cutting process changes to a plowing process, no chip is generated, and the surface quality worsens [27]. Under a constant cutting depth, the smaller the cutting speed is, the larger the shear strain ε is, and it is more likely that a plowing phenomenon occurs [30]. To avoid surface quality degradation caused by the phenomenon of plowing, orthogonal cutting tests under different uncut chip thicknesses were performed, and plowing phenomena were observed.…”

Section: Selection Of the Cutting Parametersmentioning

confidence: 99%

Precision Cutting of the Molds of an Optical Functional Texture Film with a Triangular Pyramid Texture

Huang

et al. 2020

Micromachines

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Based on an analysis of the precision and preparation technology of an optical texture film with a triangular pyramid texture, the technical requirements of the original mold were determined, and precision shaping planning technology was adopted to process the original mold. The shape error of the optical texture mold of the triangular pyramid was assessed by defining the area ratio of the retro-reflection. The influence of the tool nose radius and exit burr on the area ratio of the retro-reflection were analyzed. By optimizing the cutting tools, cutting materials and cutting boundaries, a five-axis ultra-precision machining system was used to plan the triangular pyramid structure with a base length of 115 µm and an included angle between two sides of 70.5°. The experimental results indicate that the dimension error of the triangular pyramid element is less than 1 µm, the angle error of the included angle between two sides is less than 0.05°, and the average roughness of the side of the triangular pyramid can reach 9.2 nm, which satisfies the processing quality requirements of the triangular pyramid texture mold.

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“…Experiments have revealed that ploughing width can be estimated during nanomachining of FCC crystal, considering the uncut chip thickness, radius of cutting edge, cutting direction and surface crystal orientation. Luo et al [15] proposed a 3D geometrical approach for a ball-end milling process to reliably estimate the ploughing volume of the chip. As part of this approach, authors have divided the theoretical chip into the large number of discrete elements in the range of ploughing and shearing regimes.…”

Section: Introductionmentioning

confidence: 99%

Study on ploughing phenomena in tool flank face – workpiece interface including tool wear effect during ball-end milling

Wojciechowski

Krajewska-Śpiewak

Maruda

et al. 2023

Tribology International

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Numerical simulation of chip ploughing volume in micro ball-end mill machining

Cited by 5 publications

References 8 publications

Ultra-Precision Cutting and Characterization of Reflective Convex Spherical Blazed Grating Elements

Ultra-Precision Cutting and Characterization of Reflective Convex Spherical Blazed Grating Elements

Precision Cutting of the Molds of an Optical Functional Texture Film with a Triangular Pyramid Texture

Study on ploughing phenomena in tool flank face – workpiece interface including tool wear effect during ball-end milling

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