Surface quality in micro milling: Influences of spindle and cutting parameters

Aurich, Jan C.; Bohley, Martin; Reichenbach, Ingo G.; Kirsch, Benjamin

doi:10.1016/j.cirp.2017.04.029

Cited by 64 publications

(29 citation statements)

References 5 publications

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“…In a 3D printing context, a five-axis micro milling machine can produce free-form surfaces with fairly small features. However, due to the kinematics of the milling process, it is difficult to control the surface roughness [ABRK17]. In another early technique, Matusik et al [MAG*09] use different inks in different halftoning patterns to print a surface with spatially-varying reflectance properties.…”

Section: Related Workmentioning

confidence: 99%

Microstructure Control in 3D Printing with Digital Light Processing

Luongo

Falster

Doest

et al. 2019

Computer Graphics Forum

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Digital light processing stereolithography is a promising technique for 3D printing. However, it offers little control over the surface appearance of the printed object. The printing process is typically layered, which leads to aliasing artefacts that affect surface appearance. An antialiasing option is to use greyscale pixel values in the layer images that we supply to the printer. This enables a kind of subvoxel growth control. We explore this concept and use it for editing surface microstructure. In other words, we modify the surface appearance of a printed object by applying a greyscale pattern to the surface voxels before sending the cross‐sectional layer images to the printer. We find that a smooth noise function is an excellent tool for varying surface roughness and for breaking the regularities that lead to aliasing. Conversely, we also present examples that introduce regularities to produce controlled anisotropic surface appearance. Our hope is that subvoxel growth control in stereolithography can lead 3D printing towards customizable surface appearance. The printing process adds what we call ground noise to the printed result. We suggest a way of modelling this ground noise to provide users with a tool for estimating a printer's ability to control surface reflectance.

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Section: Related Workmentioning

confidence: 99%

Microstructure Control in 3D Printing with Digital Light Processing

Luongo

Falster

Doest

et al. 2019

Computer Graphics Forum

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“…Research activities were dedicated to the surface quality improvement and to reduce the tool wear. Investigations by kinematic simulations and experiments with single edge micro end mills with an effective milling cutter diameter of 50 µm demonstrated the influence of the tilt angle of the spindle on the generated surface quality [6].…”

Section: Micro-millingmentioning

confidence: 99%

Complex Micro Machining of an Injection Mold Surface for a Conductive Polymeric Composite Product

Serban

Opran

2019

MATEC Web Conf.

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Hydrogen and fuel cell technologies were identified amongst new renewable energy technologies which contribute strongly to mitigating climate change. Important research activities were directed to the injection molded bipolar plates made by conductive polymeric composites. The mold surface quality can help obtaining better conductivity. In this paper are presented the experiments regarding complex micro-machining of the surfaces of an injection mold for a conductive polymeric composite product by micro-milling and for finishing and cleaning by laser beam micro-machining. The laser ablation consists in removing material from a solid surface by irradiating it with a laser beam, in successive layers in order to achieve complex geometries with accuracy of about micrometres. Injection moulding experiments evidenced the very good replication of the micro-machined surface pattern.

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“…Chen et al [ 6 ] established the uncut chip thickness model and an improved cutting force model of micro milling by considering the ploughing effect and elastic recovery of the workpiece material. Aurich et al [ 7 ] used single edge micro end mills with diameter of 50 μm and investigated the effects of the title angle of the spindle on the surface quality in micro milling process by kinematic simulations and experiments. Liu et al [ 8 ] disclosed that a smaller feed per tooth could make the tool material stick less easily to the titanium alloy in the micro milling process.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

et al. 2020

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Aluminum alloy material is widely used in the electronics, weapons, aviation and aerospace industries, due to its medium strength, good corrosion resistance, good toughness and excellent oxidation properties. With the trend of product miniaturization, micro cutting has become the mainstream technique for fabricating micro parts and components, so it is very meaningful and vital to work on removing the cutting fluid from the micro cutting process and make it totally sustainable and eco-friendly. In this work, an attempt has been made to fabricate micro textures onto the rear surface of helical micro end mills with diameters of less than 1 mm. Micro textures in the form of grooves were fabricated using a noncontact low speed wire electrical discharge turning technique. Dry micro cutting experiments were carried out on an aluminum alloy material using helical micro end mills with micro textures and the dry micro cutting surface quality and tool wear have been investigated. The influence of dry micro cutting parameters on the surface roughness parameters were also investigated. Experimental results showed that the Sa and Sq can be reduced to be about 1.56 μm and 2.08 μm, respectively. Contrasting results indicate that the implantation of micro textures does not deteriorate the dry micro cutting surface but improves the machined surface consistency of an aluminum alloy workpiece. The tool wear on helical micro end mills with micro textures involved in the dry micro cutting process of Al 6061 mainly include rear frictional wear, oxidation wear and diffusion wear.

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Surface quality in micro milling: Influences of spindle and cutting parameters

Cited by 64 publications

References 5 publications

Microstructure Control in 3D Printing with Digital Light Processing

Microstructure Control in 3D Printing with Digital Light Processing

Complex Micro Machining of an Injection Mold Surface for a Conductive Polymeric Composite Product

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

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