Surface Quality Optimization in Micromachining with Cutting Tool Having Regular Constructive Geometry

Dumitraş, Cătălin Gabriel; Chitariu, Dragoș Florin; Chifan, Florin; Lates, Cristina Georgiana; Horodincă, Mihăiţă

doi:10.3390/mi13030422

Cited by 6 publications

(3 citation statements)

References 15 publications

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“…The first approach to this investigation is the experimental sampling of the surface roughness description using appropriate equipment. The most common method to achieve this sampling is the use of contact profilometers [ 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 ] as a reliable but time-consuming method. Some other methods use the non-contact surface exploration by lasers [ 11 ], laser interferometry [ 12 , 13 ], laser confocal microscopes [ 14 ], optical systems [ 15 , 16 , 17 , 18 ], machine vision systems [ 19 ], or are inspired by research into the optical properties of surfaces (ability to split white light, diffractive properties) using scanning electron microscopy and atomic force microscopy [ 20 ].…”

Section: Introductionmentioning

confidence: 99%

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

Horodinca,

Chifan,

Paduraru

et al. 2024

Materials

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This paper presents a study of 2D roughness profiles on a flat surface generated on a steel workpiece by ball nose end milling with linear equidistant tool paths (pick-intervals). The exploration of the milled surface with a surface roughness tester (on the pick and feed directions) produces 2D roughness profiles that usually have periodic evolutions. These evolutions can be considered as time-dependent signals, which can be described as a sum of sinusoidal components (the wavelength of each component is considered as a period). In order to obtain a good approximate description of these sinusoidal components, two suitable signal processing techniques are used in this work: the first technique provides a direct mathematical (analytical) description and is based on computer-aided curve (signal) fitting (more accurate); the second technique (synthetic, less accurate, providing an indirect and incomplete description) is based on the spectrum generated by fast Fourier transform. This study can be seen as a way to better understand the interaction between the tool and the workpiece or to achieve a mathematical characterisation of the machined surface microgeometry in terms of roughness (e.g., its description as a collection of closely spaced 2D roughness profiles) and to characterise the workpiece material in terms of machinability by cutting.

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Section: Introductionmentioning

confidence: 99%

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

Horodinca,

Chifan,

Paduraru

et al. 2024

Materials

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“…Using multi-axis control, complex contours can be machined with excellent continuity of different pattern structures. Technological stability and relatively simple process control principles allow the use of micro-milling in the fields of medicine (production of chips for insulin pumps, various parts of implants, and dentistry), electrical engineering, and watchmaking [13][14][15][16][17][18][19][20][21][22][23][24][25].…”

Section: Introductionmentioning

confidence: 99%

Creation of an Aluminum Alloy Template with a Surface Structure by Micro-Milling for Subsequent Replication of the Microstructure to Achieve Hydrophobicity

Knap,

Dvořáčková,

Váňa

2024

JMMP

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This research paper focuses on the fabrication of a microstructure based on a natural structure pattern of hydrophobic properties using micro-milling technology, followed by an investigation of the dimensional accuracy, roughness, and replication of the fabricated microstructure. Design, modeling (CAD system), fabrication, and replication are the steps of this process. Knowledge of biomimetics was used to select the microstructure. The main research aim of the experiments is to verify and extend the applicability of conventional CNC manufacturing technologies to obtain a functional surface structure. The micro-milling was carried out on a conventional DMG MORI CNC machine, a CMX 600 V three-axis horizontal milling center, using an external high-frequency electric spindle clamped to the machine. The machined material was aluminum alloy EN AW 7075. The tool was a 0.1 mm diameter double-edged ball mill made of sintered carbide and coated with TiSiN. The cutting conditions were determined according to the tool manufacturer’s recommendations. To compare the achieved accuracies, the same microstructure was fabricated using PLA technology. For subsequent replication of the sample, the negative of the selected microstructure was created and machined. Subsequently, a positive microstructure was created using the silicone impression material by the replication process. This paper and the experiments performed extend the technical knowledge in the field of manufacturing surface functional structures and confirm the possibility of manufacturing the designed structures using chip and laser machining technology, with achieved discontinuities in the range of 3 to 50 μm. They also highlight the issues of replication of such structures with respect to critical manufacturing locations (geometrical parameters of the structures affecting the functional properties of the structure, venting, replica defects, etc.).

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“…Many studies related to the grinding process has been performed [13][14][15][16]. Qiu et al [17] investigated the effects of undeformed chip thickness and grinding speed on the morphology of grinding marks.…”

Section: Introductionmentioning

confidence: 99%

A mathematical model for the cylindrical grinding responses of 18CrNiMo7-6 alloy steel

Zhang,

Lu,

et al. 2023

Preprint

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Due to its exceptional mechanical properties, 18CrNiMo7-6 alloy steel is one of the preferred materials for producing critical components of high-speed heavy-duty gearboxes. To study the relationship between cylindrical grinding parameters, i.e., workpiece speed, wheel speed and grinding depth, and grinding responses (grinding force, temperature and surface residual stress), dimensional analysis and finite element simulation of cylindrical grinding for 18CrNiMo7-6 alloy steel are performed. A mathematical model of grinding force and residual stress of cylindrical grinding is proposed, and the numerical and experimental verifications of 18CrNiMo7-6 cylindrical alloy steel are carried out. Numerical verification shows that the maximum relative errors of grinding force and residual stress models are 7.9% and 11.2%, respectively. The experimental results reveal that the maximum absolute errors were 1.31 N and 33.7 MPa, respectively. The results indicate that the proposed model could be used as a guide for practical grinding operation, which is helpful to optimize machining parameters, improve production efficiency and ensure high quality machining results.

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Surface Quality Optimization in Micromachining with Cutting Tool Having Regular Constructive Geometry

Cited by 6 publications

References 15 publications

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill

Creation of an Aluminum Alloy Template with a Surface Structure by Micro-Milling for Subsequent Replication of the Microstructure to Achieve Hydrophobicity

A mathematical model for the cylindrical grinding responses of 18CrNiMo7-6 alloy steel

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