Optimization of micro milling of hardened steel with different grain sizes using multi-objective evolutionary algorithm

Lauro, Carlos Henrique; Filho, Sérgio Luiz Moni Ribeiro; Baldo, Denison; Cerqueira, Sérgio A. A. G.; Brandão, Lincoln Cardoso

doi:10.1016/j.measurement.2016.02.011

Cited by 13 publications

(7 citation statements)

References 26 publications

(32 reference statements)

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“…In general, the grain size of aluminum alloy is usually larger than that of titanium alloy and larger grain size corresponds to the larger minimum cutting thickness during micro-milling process, which results comparatively higher feed rate for size effect point. 5,25 From Figures 7 and 8, we can find that the position of size effect point changes with different vibration amplitudes. Under CM condition, as vibration amplitude of 0 mm, the size effect points for 6061T6 and TC4 were around feed rate of 40 and 30 mm/min, respectively.…”

Section: Size Effect Pointmentioning

confidence: 97%

“…In micro-milling, material removal in micro-milling is often characterized by significant plowing and rubbing compared to conventional scale machining. 4,5 For micro-milling, additional difficulties arise from the well-known machining size effect and the fragility of the miniature tool. 6,7 The main feature of size-effects in micro-machining is the flow stress of the material which is influenced by different types of size-effects and the most important effect in machining is the increase of the normalized cutting force with decreasing the uncut chip thickness.…”

Section: Introductionmentioning

confidence: 99%

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Machinablity improvement with ultrasonic vibration–assisted micro-milling

Han

2018

Advances in Mechanical Engineering

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An ultrasonic vibration-assisted micro-milling with horizontal vibration of workpiece is investigated in this article. A vibration platform with maximum amplitude of 15 mm based on universal ball support structure is designed and built by our group. Titanium alloy TC4 and aluminum alloy 6061T6 were chosen as workpiece material. Series of slot-milling experiments were conducted with and without vibration at different amplitudes and feed rates to explore the effects of vibration on the micro-milling. Experiment results showed that ultrasonic vibration can effectively reduce milling force by 12% and 17%, respectively, for aluminum alloy 6061T6 and titanium alloy TC4 compared with that of conventional milling and hence leading to a better machining accuracy and longer tool life. Furthermore, the effect of ultrasonic vibration on titanium alloy is much more obvious. The topographies of machined surfaces also showed that ultrasonic vibration can reduce surface defects and machining marks and thus improve the surface quality for both 6061T6 and TC4. Besides these, it is worth to be noted that ultrasonic vibration leads the size effect point appear at much lower feed rate than conventional milling, which means vibration brings a change to machining mechanism and delays the appearance of micro-milling.

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Section: Size Effect Pointmentioning

confidence: 97%

Section: Introductionmentioning

confidence: 99%

Machinablity improvement with ultrasonic vibration–assisted micro-milling

Han

2018

Advances in Mechanical Engineering

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“…In the captured images, the tool can be in any positions, and the algorithm can evaluate it correctly. This is based on the fact that the size of the tool (which perpendicular to the cutting edges of the tool) does [4], [33], [38], [46], [48], [51], [54], [83], [88], [89], [122], [133], [144], [164], [165], [166], [167], [168] AISI 1015: [169] AISI 1018: [125] AISI 1040: [77] AISI 1050: [37] AISI 4340: [119], [139], [170] AISI P20: [20], [145], [164] S960QL: [171] NAK80: [123], [172], [173], [174] AISI A2-annealed: [175] 42CrMo4: [167] X13NiMnCuAl4-2-1-1: [146] SK2: [176] Hardened steels AISI H13: [2], [30], [42], [72], [80], [164], [177], [178], [179],…”

Section: Micro-milling Process Monitoringmentioning

confidence: 99%

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

124

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Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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“…In follow-up research, Lauro et al 30 used an integrated least square model combined with a genetic algorithm to identify the optimal process parameters, that is, cutting speed, feed rate and grain size were considered. The genetic algorithm was chosen, because it is widely considered a robust and efficient optimisation method which can relatively easily be integrated into least squares algorithms.…”

Section: Literature Reviewmentioning

confidence: 99%

Material microstructure effects in micro-endmilling of Cu99.9E

Elkaseer

Dimov

Pham

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article presents an investigation of the machining response of metallurgically and mechanically modified materials at the micro-scale. Tests were conducted that involved micro-milling slots in coarse-grained Cu99.9E with an average grain size of 30 µm and ultrafine-grained Cu99.9E with an average grain size of 200 nm, produced by equal channel angular pressing. A new method based on atomic force microscope measurements is proposed for assessing the effects of material homogeneity changes on the minimum chip thickness required for a robust micro-cutting process with a minimum surface roughness. The investigation has shown that by refining the material microstructure the minimum chip thickness can be reduced and a high surface finish can be obtained. Also, it was concluded that material homogeneity improvements lead to a reduction in surface roughness and surface defects in micro-cutting

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Optimization of micro milling of hardened steel with different grain sizes using multi-objective evolutionary algorithm

Cited by 13 publications

References 26 publications

Machinablity improvement with ultrasonic vibration–assisted micro-milling

Machinablity improvement with ultrasonic vibration–assisted micro-milling

A review on micro-milling: recent advances and future trends

Material microstructure effects in micro-endmilling of Cu99.9E

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