Surface Finish of Ball-End Milled Microchannels

Berestovskyi, D.; Hung, Wayne; Lomeli, Paul

doi:10.1115/1.4028502

Cited by 17 publications

(6 citation statements)

References 12 publications

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“…In the vertical milling test, the peak shapes of both surface topographies were very similar, as shown in Figure 11; the differences in the valley were mainly attributable to the characteristics of ball-end vertical milling: the velocity of the cutter's bottom is low, and the leading effects of squeezing and ploughing cause the part's material to undergo plastic flow and deformation. Cutter wear, especially in the ball head, may also have a certain effect on the formation of micro surface topography [44]. There were some differences near the bottom valleys of the sectional profiles shown in Figure 11c, because the larger slippage and plastic flow of the metal cutting layer mainly appeared in the leading feed direction.…”

Section: Experimental Validationmentioning

confidence: 99%

Modeling and Analysis of Micro Surface Topography from Ball-End Milling in a Trochoidal Milling Mode

Dong

Zhang

et al. 2021

Micromachines

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The trochoidal milling mode is widely used in high-speed machining, and due to good adaptability and flexible posture adjustment, ball-end milling cutters are conducive to complex surface machining with this mode. However, the processes of material removal and formation of machined micro surfaces are very difficult to describe as the profile of cutter teeth is complex and the trajectory direction changes continuously during the trochoidal milling process. A modeling method for the generation of micro surface topography of ball-end milling in the trochoidal milling mode is put forward. In this method, the locus equation of each cutter tooth is established based on the principle of homogeneous coordinate transformation, after which a Z-MAP algorithm is designed to simulate the micro surface topography. The Z-MAP algorithm can quickly obtain the part grid nodes potentially swept by the cutter tooth within a unit time step through the establishment of servo rectangular encirclement and instantaneous sweeping quadrilateral of the element of cutter teeth; the part grid nodes actually swept are further determined through an angle summation method, and the height coordinate is calculated with the method of linear interpolation according to Taylor’s formula of multivariate functions. Experiments showed that the micro surface topography resulting from ball-end milling in the trochoidal milling mode had high consistency with the simulation, which indicates that the proposed method can predict micro surface topography in practical manufacturing. In addition, a comparison of micro surface topography between trochoidal milling and ordinary straight-linear milling was conducted, and the results showed that the former was overall superior to the latter in resulting characteristics. Based on this conclusion, the influences of cutting parameters of ball-end trochoidal milling on surface characteristics, particularly amplitude and function, were analyzed according to the simulated micro surface topography data.

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Section: Experimental Validationmentioning

confidence: 99%

Modeling and Analysis of Micro Surface Topography from Ball-End Milling in a Trochoidal Milling Mode

Dong

Zhang

et al. 2021

Micromachines

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“…For example, the experiment with a feed rate of 2 µm/flute on the sixth needle (Table 4b) has some burrs (white oval) adhered to the surface, while burrs are more evident using the highest feed rate (3 µm/flute) in needles twelfth and eighteenth (Table 4b). Berestovskyi et al explained that build -up-edges (BUE) worsens surface finish and increases burr formation, however BUE and wear of the tool can be minimized with coated tools and applying MQL [29]. Additionally, according to Vazquez et al [22] the use of MQL in microscale allows wetting the tool tip compared to traditional lubrication flood cooling which causes a disordered flow.…”

Section: Dimensional and Surface Characterizationmentioning

confidence: 99%

Evaluation of Ball End Micromilling for Ti6Al4V ELI Microneedles Using a Nanoadditive Under MQL Condition

Celis

Vázquez

Soria-Hernández

et al. 2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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The use of nanoadditives in lubricants has gained much attention to the research community due to the enhancement of tribological properties and cooling capabilities. This paper studies the advantages of using a MQL (Minimum Quantity of Lubrication) system and nanoadditive in the manufacture of microneedle arrays in Ti6Al4V ELI alloy. Tungsten carbide ball nose tools with a cutting diameter of 200 µm were used in experimental tests. Surface and dimensional characterization was performed to evaluate the impact of a nanoadditive to a vegetable-based oil. Additionally, cutting forces and cutting edge radius (CER) were measured while needles were machined. Experimental tests confirmed that micro end milling with nanoadditives provide slightly better dimensional features and low cutting forces compared to oil. The performance of nanoadditives resulted in a reduction of surface roughness (~ 0.3 μm). Qualitative study of microneedles illustrated burr formation on needle surface manufactured without a nanoadditive solution. Results reveal an increment of CER using low feed rate values (2.0 µm/flute) while a reduction of CER was observed with feed rates up to 2.5 µm/flute. Our results indicated that the addition of nanoadditives to vegetable oil promotes a better product surface topography and cutting tool performance.

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“…Average surface finish at center of milled microchannels. Ball-end milling tools ϕ152-9525 μm, workpiece materials 6061-T6, A36 steel, NiTi, 304/316L stainless steels, in MQL condition [19].…”

Section: Micromillingmentioning

confidence: 99%

“…Effect of tool coating on resulting burrs: (a) uncoated ϕ152 μm tool, milling 304 stainless steel, 24 m/min, 0.1 μm/tooth, MQL; and (b) AlTiN coated ϕ198 μm tool, milling 304 stainless steel, 24 m/min, 0.1 μm/tooth, MQL[19].…”

mentioning

confidence: 99%

Micromachining of Advanced Materials

Hung¹,

Corliss²

2019

Micromachining

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Market needs often require miniaturized products for portability, size/weight reduction while increasing product capacity. Utilizing additive manufacturing to achieve a complex and functional metallic part has attracted considerable interests in both industry and academia. However, the resulted rough surfaces and low tolerances of as-printed parts require additional steps for microstructure modification, physical and mechanical properties enhancement, and improvement of dimensional/form/surface to meet engineering specifications. Micromachining can (i) produce miniature components or microfeatures on a larger component, and (ii) enhance the quality of additively manufactured metallic components. This chapter suggests the necessary requirements for successful micromachining and cites the research studies on micromachining of metallic materials fabricated by either traditional route or additive technique. Micromachining by nontraditional techniques-e.g., ion/electron beam machining-are beyond the scope of this chapter. The chapter is organized as following:

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Surface Finish of Ball-End Milled Microchannels

Cited by 17 publications

References 12 publications

Modeling and Analysis of Micro Surface Topography from Ball-End Milling in a Trochoidal Milling Mode

Modeling and Analysis of Micro Surface Topography from Ball-End Milling in a Trochoidal Milling Mode

Evaluation of Ball End Micromilling for Ti6Al4V ELI Microneedles Using a Nanoadditive Under MQL Condition

Micromachining of Advanced Materials

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