Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy

Abstract

This comprehensive study investigates the micro-milling of a Mg13Sn alloy, a material of considerable interest in various high-precision applications, such as biomedical implants. The main objective of the study was to explore the optimizations of variable feed per tooth (fz), cutting speed (Vc), and depth of cut (ap) parameters on the key outcomes of the micro-milling process. A unique experimental setup was employed, employing a spindle capable of achieving up to 60,000 revolutions per minute. Additionally, the study leveraged linear slides backed by micro-step motors to facilitate precise axis movements, thereby maintaining a resolution accuracy of 0.1 μm. Cutting forces were accurately captured by a mini dynamometer and subsequently evaluated based on the peak to valley values for Fx (tangential force) and Fy (feed force). The study results revealed a clear and complex interplay between the varied cutting parameters and their subsequent impacts on the cutting forces and surface roughness. An increase in feed rate and depth of cut significantly increased the cutting forces. However, the cutting forces were found to decrease noticeably with the elevation of cutting speed. Intriguingly, the tangential force (Fx) was consistently higher than the feed force (Fy). Simultaneously, the study determined that the surface roughness, denoted by Sa values, increased in direct proportion to the feed rate. It was also found that the Sa surface roughness values decreased with the increase in cutting speed. This study recommends a parameter combination of fz = 5 µm/tooth feed rate, Vc = 62.8 m/min cutting speed, and ap = 400 µm depth of cut to maintain a Sa surface roughness value of less than 1 µm while ensuring an optimal material removal rate and machining time. The results derived from this study offer vital insights into the micro-milling of Mg13Sn alloys and contribute to the current body of knowledge on the topic.

Design Parameters Optimization in CNC Machining Based on Taguchi, ANOVA, and Screening Method

“…From Table 5 can be seen that vc, vf, and doc, are lower probabilities compared to other parameters, where they have a significant effect on the response Ra. Similar results of Ra can be found in [31] and [30]. By VIF equal to 1 at all parameters indicated that they have no correlations among the predictors in the model.…”

Improvement of Analytical Model for Oblique Cutting—Part I: Identification of Mechanical Characteristics of Machined Material

“…However, it differed from the previous one in that it took into account the influence of tool edge radius on tool clearance face wear in the micro-end milling process. The study by Ercetin and colleagues is devoted to the consideration of machining parameter optimization issues for minimizing cutting forces and surface roughness in the micro-milling of Mg13Sn alloy [77]. Cai L. and colleagues proposed an analytical model for calculating the temperature during milling with minimum quantity lubrication (MQL) of AISI D2 steel [78].…”

Dynamic Modeling for Chatter Analysis in Micro-Milling by Integrating Effects of Centrifugal Force, Gyroscopic Moment, and Tool Runout

“…The main influencing factors must include the dynamic motions of the spindle-holder-tool assembly. During cutting, the spindle speed of the micro-machine is usually higher than 10,000 revolutions per minute to ensure a high cutting efficiency in micro-milling [3]. Therefore, the centrifugal force induced by rotational speeds and the gyroscopic effect induced by high speeds are inevitably accompanied by high spindle speeds.…”