Surface generation analysis in micro end-milling considering the influences of grain

Wang, J. S.; Gong, Yadong; Abba, Gabriel; Chen, K.; Shi, Jiashun; Cai, Guang Qi

doi:10.1007/s00542-007-0478-y

Cited by 34 publications

(7 citation statements)

References 6 publications

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“…Also, due to the significant variations in the minimum chip thickness over the scan area for the CG sample, the cutting process would be unstable and would result in highly fragmented chips and defects in the machined surfaces. 42 Conversely, the high homogeneity of the UFG Cu samples results in much less variation in the coefficient of friction and hence in the minimum chip thickness over the scanned area. Therefore, the cutting process would be expected to be more stable and the defects on the machined surfaces to decrease.…”

Section: Experimental Set-upmentioning

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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Section: Experimental Set-upmentioning

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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“…To analyze the material flow in micro cutting, the stagnation point (S) is considered on the cutting edge of the tool; above this point a chip is formed and below only the elastic-plastic deformation takes place [31,32]. As the undeformed chip thickness (h c ) reduces in micromachining, the positive rake angle of the tool (+γ tool ), shown in Figure 1d [33], is not the actual rake angle participating in the material removal process. The effective rake angle becomes negative (−γ eff ) as the value of UCT (h c ) reaches much smaller than the size of CER (r).…”

Section: Introductionmentioning

confidence: 99%

“…A recent study of conventional longitudinal turning with Mg-Al alloy has shown that feed rate has the most significant impact on surface roughness and machined Figure 1. Schematic of (a) 3D view of orthogonal cutting with single-point cutting tool [28] (b) 2D view of macro machining model [29] (c) 2D view of micromachining model [30] (d) 2D view of ploughing in micromachining [33]. Copyright Permission obtained.…”

Section: Introductionmentioning

confidence: 99%

Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy

Rahman

Bhuiyan

Sharma

et al. 2021

Metals

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In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.

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“…It is characterized by the mechanical interaction between a sharp edged microtool and a workpiece material. Micromilling is similar to macro milling except for the tool size it employs [1][2][3][4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Effect of Minimum Quantity Lubrication on Surface Roughness in Tool-Based Micromilling

Ali

Jailani

Rahman

et al. 2017

IIUMEJ

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Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

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Surface generation analysis in micro end-milling considering the influences of grain

Cited by 34 publications

References 6 publications

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

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

Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy

Effect of Minimum Quantity Lubrication on Surface Roughness in Tool-Based Micromilling

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