scholarly journals Improved Process Geometry Model with Cutter Runout and Elastic Recovery in Micro-end Milling

2016 ◽  
Vol 5 ◽  
pp. 478-494 ◽  
Author(s):  
Tesfaye M. Moges ◽  
K.A. Desai ◽  
P.V.M. Rao
Keyword(s):  
End Milling ◽  
Elastic Recovery ◽  
Cutter Runout ◽  
Geometry Model ◽  
Micro End Milling

A New Mechanistic Approach for Micro End Milling Force Modeling

2010 ◽  
Author(s):  
Martin B. G. Jun ◽  
Chanseo Goo ◽  
Mohammad Malekian ◽  
Simon S. Park
Keyword(s):  
End Milling ◽  
Elastic Recovery ◽  
Rake Angle ◽  
Mechanistic Modeling ◽  
Force Modeling ◽  
Edge Radius ◽  
Effective Rake Angle ◽  
Wide Range ◽  
Micro End Milling ◽  
Milling Forces

This paper investigates the mechanistic modeling of micro end milling forces, with consideration of the effects of plowing, elastic recovery, effective rake angle, and flank face rubbing. Two different mechanistic models are developed for shearing- and plowing-dominant regimes. Micro end milling experiments are conducted to validate the model for Aluminum 6061; and, the model appropriately predicts force profiles for a wide range of feed rates, and prediction of the root mean square (RMS) values of the resultant forces is, on average, within a 12% error. The study of the model shows that plowing and rubbing force contributions are significant, especially at low feed rates. The edge radius is found to have a significant effect on plowing and rubbing force components and the effective rake angle, which indicates that it is important to maintain a low edge radius to reduce micro end milling forces.

A New Mechanistic Approach for Micro End Milling Force Modeling

2012 ◽  
Vol 134 (1) ◽  
Author(s):  
Martin B. G. Jun ◽  
Chanseo Goo ◽  
Mohammad Malekian ◽  
Simon Park
Keyword(s):  
End Milling ◽  
Elastic Recovery ◽  
Rake Angle ◽  
Mechanistic Modeling ◽  
Force Modeling ◽  
Edge Radius ◽  
Effective Rake Angle ◽  
Wide Range ◽  
Micro End Milling ◽  
Milling Forces

This paper investigates the mechanistic modeling of micro end milling forces, with consideration of the effects of plowing, elastic recovery, effective rake angle, and flank face rubbing. Two different mechanistic models are developed for shearing- and plowing-dominant regimes. Micro end milling experiments are conducted to validate the model for Aluminum 6061; and, the model appropriately predicts force profiles for a wide range of feed rates, and prediction of the root mean square (RMS) values of the resultant forces is, on average, within a 12% error. The study of the model shows that plowing and rubbing force contributions are significant, especially at low feed rates. The edge radius is found to have a significant effect on plowing and rubbing force components and the effective rake angle, which indicates that it is important to maintain a low edge radius to reduce micro end milling forces.

scholarly journals Fabrication and characterization of resistive double square loop arrays for ultra-wide bandwidth microwave absorption

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Ji-Young Jeong ◽  
Je-Ryung Lee ◽  
Hyeonjin Park ◽  
Joonkyo Jung ◽  
Doo-Sun Choi ◽  
...  
Keyword(s):  
Sheet Resistance ◽  
Manufacturing Process ◽  
End Milling ◽  
Milling Process ◽  
Wide Bandwidth ◽  
Machined Surface ◽  
Array Pattern ◽  
Micro End Milling ◽  
Array Structures ◽  
Printing Processes

AbstractMicrowave absorbers using conductive ink are generally fabricated by printing an array pattern on a substrate to generate electromagnetic fields. However, screen printing processes are difficult to vary the sheet resistance values for different regions of the pattern on the same layer, because the printing process deposits materials at the same height over the entire surface of substrate. In this study, a promising manufacturing process was suggested for engraved resistive double square loop arrays with ultra-wide bandwidth microwave. The developed manufacturing process consists of a micro-end-milling, inking, and planing processes. A 144-number of double square loop array was precisely machined on a polymethyl methacrylate workpiece with the micro-end-milling process. After engraving array structures, the machined surface was completely covered with the developed conductive carbon ink with a sheet resistance of 15 Ω/sq. It was cured at room temperature. Excluding the ink that filled the machined double square loop array, overflowed ink was removed with the planing process to achieve full filled and isolated resistive array patterns. The fabricated microwave absorber showed a small radar cross-section with reflectance less than − 10 dB in the frequency band range of 8.0–14.6 GHz.

scholarly journals Multilayer Diamond Coatings Applied to Micro-End-Milling of Cemented Carbide

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3333
Author(s):  
Eduardo L. Silva ◽  
Sérgio Pratas ◽  
Miguel A. Neto ◽  
Cristina M. Fernandes ◽  
Daniel Figueiredo ◽  
...  
Keyword(s):  
Electron Microscopy ◽  
End Milling ◽  
Interfacial Stress ◽  
Cemented Carbide ◽  
Air Cooling ◽  
Micro Machining ◽  
Diamond Coatings ◽  
Wear Properties ◽  
High Adhesion ◽  
Micro End Milling

Cobalt-cemented carbide micro-end mills were coated with diamond grown by chemical vapor deposition (CVD), with the purpose of micro-machining cemented carbides. The diamond coatings were designed with a multilayer architecture, alternating between sub-microcrystalline and nanocrystalline diamond layers. The structure of the coatings was studied by transmission electron microscopy. High adhesion to the chemically pre-treated WC-7Co tool substrates was observed by Rockwell C indentation, with the diamond coatings withstanding a critical load of 1250 N. The coated tools were tested for micro-end-milling of WC-15Co under air-cooling conditions, being able to cut more than 6500 m over a period of 120 min, after which a flank wear of 47.8 μm was attained. The machining performance and wear behavior of the micro-cutters was studied by scanning electron microscopy and energy-dispersive X-ray spectroscopy. Crystallographic analysis through cross-sectional selected area electron diffraction patterns, along with characterization in dark-field and HRTEM modes, provided a possible correlation between interfacial stress relaxation and wear properties of the coatings. Overall, this work demonstrates that high adhesion of diamond coatings can be achieved by proper combination of chemical attack and coating architecture. By preventing catastrophic delamination, multilayer CVD diamond coatings are central towards the enhancement of the wear properties and mechanical robustness of carbide tools used for micro-machining of ultra-hard materials.

Prediction of Burr Formation in Fabricating MEMS Components by Micro End Milling

2009 ◽  
Vol 74 ◽  
pp. 247-250 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Mohd Aliff Omar ◽  
Khairul Irman Othman ◽  
Wayne N.P. Hung
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Burr Formation ◽  
Aisi 304 ◽  
Burr Height ◽  
Milling Parameters ◽  
Milling Tool ◽  
Micro End Milling ◽  
Chip Load

This paper discusses burr formation in micromilling of AISI 304 stainless steel. Chip load, cutting speed and the application of coolant were chosen as the milling parameters. Experiments were conducted using 500 µm diameter tungsten carbide end milling tool. Milling parameters and measured burr height values were analyzed and statistical models were developed for the estimation of burr height. The models showed that the chip load and cutting speed both have direct and interactive contribution to burr formation. When micromachining without coolant, the burr height increases about 40% compared to that of machining with coolant. The optimized values of chip load and cutting speed were found to be 1 µm/tooth and 78 mms-1 respectively. The predicted burr heights were 5-7% larger than that of measured values.

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