Size effect and tool geometry in micromilling of tool steel

Aramcharoen, Ampara; Mativenga, Paul

doi:10.1016/j.precisioneng.2008.11.002

Cited by 307 publications

(142 citation statements)

References 27 publications

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“…Based on this relationship, an initial approach, was to assume that the underlying mechanism for chip formation and removal had no significant difference between the macro-scale and the micro-scale. Later studies confirmed that such assumption could not be guaranteed due to a phenomenon called size effect and minimum chip thickness [10,15,17]. At small chip thicknesses, the specific energy required to remove a unit amount of material increases, which is often referred to as the size effect [17].…”

Section: Size Effectmentioning

confidence: 99%

See 1 more Smart Citation

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Giraldo¹,

Serje²,

Bolívar³

et al. 2017

DYNA

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Micro-machining of different polymer based components often require high precision and excellent surface quality at high production rates with low costs. Micro-milling is a cost-efficient micro-machining process capable of generating complex shapes in a wide range of materials. Challenges based on size effect, burr formation and adequate chip removal must be faced and are addressed in this research. Material removal mechanisms, as well as its impact on burr formation and control are reviewed, followed by a case study through the application of gaseous cooling based on vortex tubes. Different vortex generator configurations were tested, proving to be fast response an economically-friendly alternative for burr reduction while micro-milling biopolymers. Configurations, as mentioned above, were used for biopolymer micro-milling towards burr measurement after each test; achieving as a result, a burr reduction while cooling temperature decreases.Keywords: Micro-milling; Burr; Polymer machining; Vortex cooling.Formación de rebabas y su control para el micro-fresado de polímeros: Un caso de estudio con refrigeración por tubo vortex Resumen El micro-maquinado de diferentes componentes basados en polímeros a menudo requiere de gran precisión y un excelente acabado superficial a unas tasas elevadas de producción con un bajo costo. El micro-fresado es un proceso costo-efectivo de micro-maquinado capaz de generar formas complejas en una amplia variedad de materiales. Retos basados en el efecto tamaño, formación de rebabas y una adecuada remoción de la viruta deben ser enfrentados y son tratados en la presente investigación. Los mecanismos de remoción de material, al igual que su impacto en la formación de rebabas y su control, son revisados, acompañados de un caso de estudio a través de la aplicación de refrigeración gaseosa basada en tubos vortex. Diferentes configuraciones de generadores de vortex son probados, demostrando ser una alternativa de respuesta rápida, económica y amigable para la reducción de rebabas mientras se micro-fresan biopolímeros. Dichas configuraciones se utilizaron en el micro-mecanizado de un polímero bio-compatible, midiendo el tamaño de rebaba que se genera en cada prueba, dando como resultado la disminución de estas a media que baja la temperatura de refrigeración.Palabras clave: Micro-fresado; Rebaba; Maquinado de polímeros; Refrigeración con tubo vortex.

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Section: Size Effectmentioning

confidence: 99%

“…In SAE 1045 Steel, Weule et al [20] showed that an increase in micro-milling cutting velocities led to less burr formation. Aramcharoen et al [15] noted that burr size is significantly affected by tool geometry and coatings with favorable rounded cutting edges or chamfered geometries for better quality.…”

Section: Burr Formationmentioning

confidence: 99%

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Giraldo¹,

Serje²,

Bolívar³

et al. 2017

DYNA

View full text Add to dashboard Cite

show abstract

“…Unlike in conventional macro-scale machining, undeformed chip thickness can be typically comparable in size to the cutting edge radius. This size effect is well identified in micro-milling and strongly impacts the performance of the tool [4] and the surface generation [5]. The dimensional characteristics of these tools accentuate deflection [6] and dynamic instability [7].…”

Section: Introductionmentioning

confidence: 97%

Experimental Investigation in Micro Ball-End Milling of Hardened Steel

Escolle¹,

Fontaine²,

Gilbin³

et al. 2015

JMSE-A

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Abstract:The study focuses on micro-milling of a hardened tool steel with micro ball-end mills. The purpose is to observe the capability of a set of these mills to machine hard steels used for tooling applications. Different cutting configurations are here tested in order to evaluate their performance and finally enhance their design in this context. Experimental data, in terms of cutting forces, surfaces integrity and machining errors, is obtained from machining tests on a 40NiCrMo16 hardened steel with 0.5 mm diameter coated tungsten carbide micro-tools. The results allow highlighting some cutting, wear and dynamical phenomena related to the process. They are mainly associated to the types of mill and cutting conditions, as feed or tool/surface inclination. In this paper, the tool geometry and its dynamical behavior are mainly discussed.

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“…In practice, essential product attributes in micro machined parts are nano-range surface finish, high dimensional accuracy and minimal burr size. To meet these requirements the selection of optimum cutting conditions and adequate monitoring systems are essential but demanding [6]. In most cases, in order to avoid negative impacts of tool wear in part quality, conservative cutting conditions are set, lowering the productivity and increasing manufacturing costs.…”

Section: Introductionmentioning

confidence: 99%

Adaptive control optimization in micro-milling of hardened steels—evaluation of optimization approaches

Coppel

Abellán-Nebot

Siller

et al. 2015

Int J Adv Manuf Technol

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Nowadays, the miniaturization of many consumer products is extending the use of micro-milling operations with high quality requirements. However, the impacts of cutting-tool wear on part dimensions, form and surface integrity are not negligible and part quality assurance for a minimum production cost is a challenging task. In fact, industrial practices usually set conservative cutting parameters and early cutting replacement policies in order to minimize the impact of cutting-tool wear on part quality. Although these practices may ensure part integrity, the production cost is far away to be minimized, especially in highly tool-consuming operations like mold and die micromanufacturing. In this paper, an Adaptive Control Optimization (ACO) system is proposed to estimate cutting-tool wear in terms of part quality and adapt the cutting conditions accordingly in order to minimize the production cost, ensuring quality specifications in hardened steel micro-parts. The ACO system is based on: i) a monitoring sensor system composed of a dynamometer; ii) an estimation module with Artificial Neural Networks models; iii) an optimization module with evolutionary optimization algorithms; and iv) a CNC interface module. In order to operate in a nearly real time basis and facilitate the implementation of the ACO system, different evolutionary optimization algorithms are evaluated such as Particle Swarm Optimization (PSO), Genetic Algorithms (GA) and Simulated Annealing (SA) in terms of accuracy, precision and robustness. The results for a given micro-milling operation showed that PSO algorithm performs better than GA and SA algorithms under computing time constraints. Furthermore, the implementation of the final ACO system reported a decrease in the production cost of 12.3% and 29% in comparison with conservative and high production strategies, respectively.

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Size effect and tool geometry in micromilling of tool steel

Cited by 307 publications

References 27 publications

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Experimental Investigation in Micro Ball-End Milling of Hardened Steel

Adaptive control optimization in micro-milling of hardened steels—evaluation of optimization approaches

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