Three wagons method applied: optimization of level of surface roughness within ductile mode grinding of tungsten carbide molds

2018 ◽  
Author(s):  
Oliver W. Fähnle ◽  
Marius Doetz ◽  
Olaf Dambon ◽  
Fritz Klocke ◽  
Eckhard Langenbach
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Ductile Mode ◽  
Applied Optimization

Precision Cutting of Ceramics with Milling Tool of Single Crystalline Diamond

2015 ◽  
Vol 9 (1) ◽  
pp. 26-32 ◽  
Author(s):  
Hirofumi Suzuki ◽  
◽  
Mutsumi Okada ◽  
Koichi Okada ◽  
Yosuke Ito ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Laser Beam ◽  
Tungsten Carbide ◽  
Micro Milling ◽  
Form Accuracy ◽  
Single Crystalline ◽  
Flat Shape ◽  
Ductile Mode ◽  
Milling Tool ◽  
Milling Tools

Micro milling tools made of Single Crystalline Diamond (SCD) have been developed to machine micro dies and molds made of ceramics. The milling tools of a cylindrical SCD having many sharp cutting edges are fabricated 3-dimensionally by scanning a laser beam. Flat shape of binder-less tungsten carbide mold was cut with the developed milling tool to evaluate the tool wears and its life. Some micro aspheric molds of tungsten carbide were cut with the milling tool at a rotational speed of 50,000 min-1. The ceramic molds were cut in the ductile mode. By cutting with the milling tool, the form accuracy obtained was about 100 nm P–V and the surface roughness 8 nm Rz.

Prediction of Surface Roughness in Compressed Air Jet Assisted High Speed End Milling of Silicon Using Diamond Coated Tools

2012 ◽  
Vol 576 ◽  
pp. 41-45
Author(s):  
A.K.M. Nurul Amin ◽  
M.A. Mahmud ◽  
M.D. Arif
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Surface Finish ◽  
High Speed ◽  
End Milling ◽  
Silicon Wafers ◽  
Compressed Air ◽  
Machining Parameters ◽  
High Quality ◽  
Ductile Mode

The majority of semiconductor devices are made up of silicon wafers. Manufacturing of high-quality silicon wafers includes numerous machining processes, including end milling. In order to end mill silicon to a nano-meteric surface finish, it is crucial to determine the effect of machining parameters, which influence the machining transition from brittle to ductile mode. Thus, this paper presents a novel experimental technique to study the effects of machining parameters in high speed end milling of silicon. The application of compressed air, in order to blow away the chips formed, is also investigated. The machining parameters’ ranges which facilitate the transition from brittle to ductile mode cutting as well as enable the attainment of high quality surface finish and integrity are identified. Mathematical model of the response parameter, the average surface roughness (Ra) is subsequently developed using RSM in terms of the machining parameters. The model was determined, by Analysis of Variance (ANOVA), to have a confidence level of 95%. The experimental results show that the developed mathematical model can effectively describe the performance indicators within the controlled limits of the factors that are being considered.

Surface Modification Process by Electrical Discharge Machining with Tungsten Carbide Powder Mixing in Kerosene Fluid

2019 ◽  
Vol 889 ◽  
pp. 115-122
Author(s):  
Van Tao Le ◽  
Tien Long Banh ◽  
Xuan Thai Tran ◽  
Nguyen Thi Hong Minh
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Electrical Discharge ◽  
Alloy Powder ◽  
Electrical Discharge Machining ◽  
Carbide Powder ◽  
Micro Hardness ◽  
Hard Materials ◽  
Tungsten Carbide Powder ◽  
Better Than

Electrical discharge machining (EDM) process is widely used to process hard materials in the industry. The process of electrical discharge is changed and called PMEDM when alloy powder is added in the oil dielectric. In the current study, the effect of tungsten carbide alloy powder added in the dielectric on the surface roughness (Ra) and the micro hardness of surface (HV) status of the workpiece SKD61 after machining is investigated. Studies show that the surface roughness and the micro hardness of surface obtained by PMEDM is generally better than that by normal EDM. The method can be applied for improving surface quality such as improving strengthening of molds and machine parts.

scholarly journals Experimental Investigation on Micro Milling of Polyester/Halloysite Nano-Clay Nanocomposites

Nanomaterials ◽  
2019 ◽  
Vol 9 (7) ◽  
pp. 917 ◽  
Author(s):  
Guoyu Fu ◽  
Dehong Huo ◽  
Islam Shyha ◽  
Ketan Pancholi ◽  
Mohd Shahneel Saharudin
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Flank Wear ◽  
Micro Milling ◽  
Clay Nanocomposites ◽  
Workpiece Material ◽  
Ductile Mode ◽  
Nano Clay ◽  
Surface Breakage ◽  
Mode A

Efficient machining of the polyester nanocomposite components requires a better understanding of machinability characteristics of such material, which has become an urgent requirement for modern industrial production. In this research, the micro-milling of polyester/halloysite nano-clay (0.1, 0.3, 0.7, 1.0 wt%) nanocomposites were carried out and the outcomes in terms of tool wear, cutting force, the size effect, surface morphology, and surface roughness were compared with those for plain polyester. In order to accomplish the machining of the material in ductile mode, the required feed per tooth was found to be below 0.3 µm. The degree of surface breakage was also found to decrease in ductile mode. A maximum flank wear VB of 0.012 mm after removing 196 mm3 of workpiece material was measured.

A Polishing Method of Single-Incentive Ultrasonic Elliptical Vibration for Tungsten Carbide Mould

2011 ◽  
Vol 175 ◽  
pp. 140-144 ◽  
Author(s):  
Shao Hui Yin ◽  
Zhi Qiang Xu ◽  
Jian Wu Yu ◽  
Ze Biao Wang
Keyword(s):  
Surface Roughness ◽  
Finite Element ◽  
Tungsten Carbide ◽  
Ultrasonic Transducer ◽  
Experimental Result ◽  
Basic Principles ◽  
Elliptical Vibration ◽  
Element Simulation ◽  
Mould Surface ◽  
Ultrasonic Elliptical Vibration

The basic principles of ultrasonic transducer and ultrasonic elliptical vibration polishing are investigated. A new kind of single-incentive ultrasonic transducer is designed, and the finite element simulation is conducted, a polishing device is developed based on the ultrasonic elliptical vibration. The polishing experiment is adopted to polish a tungsten carbide mold with the diameter 5cm. The experimental result shows that the tungsten carbide mould surface roughness changes from the original 0.026μm to 0.017μm.

Thermal Analysis of Laser Irradiation of Fused Silica

2011 ◽  
Vol 314-316 ◽  
pp. 1960-1964 ◽  
Author(s):  
Peng Yao ◽  
Ya Dong Gong ◽  
Suo Xian Yuan ◽  
Tian Feng Zhou ◽  
Ji Wang Yan ◽  
...  
Keyword(s):  
Thermal Analysis ◽  
Surface Roughness ◽  
Laser Irradiation ◽  
Fused Silica ◽  
Maximum Temperature ◽  
Precision Grinding ◽  
Micro Cracks ◽  
Ductile Mode ◽  
Ultra Precision ◽  
Simulation Results

To grind fused silica in ductile mode, surface and subsurface micro cracks (SSMC) on ground fused silica should be repaired by CO2 laser irradiation before ultra-precision grinding. In this paper, 2D thermal analysis of single pass laser irradiation of fused silica was conducted, and the simulation results were discussed by comparing with the experiment results. To repair SSMC and decrease the surface roughness of ground fused silica simultaneously, the maximum temperature on the surface during laser irradiation should be controlled higher than 3280 K and lower than 3550 K.

Surface characteristics and machining performance of TiAlN-, TiN- and AlCrN-coated tungsten carbide drills

2018 ◽  
Vol 233 (4) ◽  
pp. 1075-1086 ◽  
Author(s):  
Chaiya Dumkum ◽  
Pakin Jaritngam ◽  
Viboon Tangwarodomnukun
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Thrust Force ◽  
Surface Characteristics ◽  
Average Error ◽  
Force Model ◽  
Machining Performance ◽  
Coating Materials ◽  
Drilling Performance

This article presents a comprehensive analysis of surface characteristics and drilling performance of uncoated and coated tungsten carbide drills. The single- and double-layer coatings of TiN, TiAlN and AlCrN were examined in terms of surface roughness, microhardness and crack resistance. In addition, drilling torque and thrust force were experimentally measured and compared to the developed models based on the drilling mechanics and drill geometries. Tool wear and hole surface roughness were also considered to assess the machining performance of different coated tools. The results revealed that all coated drills can offer better cut surface quality, 28% lower cutting loads and longer tool life than the uncoated drills. Although AlCrN was found to be the hardest coating material among the others, it caused large wear on the cutting edges and poor surface roughness of produced holes. The lowest torque and thrust force were achievable using TiN-coated drill, while the use of TiAlN coating resulted in the lowest surface roughness and smallest tool wear. Furthermore, the drilling torque and thrust force model developed in this study were found to correspond to the experimental measures with the average error of 8.4%. The findings of this work could facilitate the selection of coating materials to advance the machining performance.

PREDICTION AND INVESTIGATION OF SURFACE ROUGHNESS WHILE TURNING SG IRON WITH CUBIC BORON NITRIDE (CBN) AND TUNGSTEN CARBIDE INSERTS

2017 ◽  
Vol 41 (1) ◽  
pp. 129-141 ◽  
Author(s):  
K.M. Kumar ◽  
P. Hariharan
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Tungsten Carbide ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Spheroidal Graphite ◽  
Surface Model ◽  
Sg Iron ◽  
The Impact

This work compares the effect of cubic boron nitride (CBN) and multilayer (TiCN+Al2O3+TiN) coated tungsten carbide (WC) tools during the turning of spheroidal graphite (SG) nodular iron. Nodular irons have more ductility which is required in mechanical components that demand high fatigue resistance like crankshafts, cam shafts, bearing caps and clutch housings. The impact of various process parameters like the depth of cut, cutting speed and feed on the surface roughness (Ra) of SG iron is studied and optimized using the response surface model. The chip morphology is also discussed for evaluation of the quality of the turned surface. The experimental outcomes reveal that the WC tool offers a high surface finish at the optimal combination of the cutting speed at 102 meter/minute, feed at 0.051 millimeter/revolution and depth of cut at 0.5 millimeter and that, for the CBN insert, at 245 meter/minute of cutting speed, 0.051 millimeter/revolution of feed and 0.75 millimeter of depth of cut.

Applicability of Diamond-Coated Tools for Ball End Milling of Sintered Tungsten Carbide

2020 ◽  
Vol 14 (1) ◽  
pp. 18-25
Author(s):  
Haruhiko Suwa ◽  
Soushi Sakamoto ◽  
Masafumi Nagata ◽  
Kazuhiro Tezuka ◽  
Tetsuo Samukawa ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
End Milling ◽  
High Hardness ◽  
High Heat ◽  
Point Of View ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Sintered Tungsten

Sintered tungsten carbide which has high hardness and high heat resistance, has been widely used in molds and dies. Research on the development of a cutting technology for sintered tungsten carbide (sintered WC-Co alloy) has been pursued mainly with the use of a turning process. We focused on building an efficient milling method for sintered tungsten carbide by using diamond-coated ball end tools, and have investigated their basic properties under specific cutting conditions. This study extends our previous work by enhancing cutting distance in the milling of sintered tungsten carbide, especially that with a “fine” WC grain. The surface roughness of cut workpieces is evaluated from the point of view of the quality of surface roughness. A series of cutting experiments under different cutting conditions were carried out, and the possibility of deriving a suitable cutting condition for the ball end milling of sintered tungsten carbide is discussed.

Precision Cutting of Structured Ceramic Molds with Micro PCD Milling Tool

2011 ◽  
Vol 5 (3) ◽  
pp. 277-282 ◽  
Author(s):  
Hirofumi Suzuki ◽  
◽  
Tatsuya Furuki ◽  
Mutsumi Okada ◽  
Katsuji Fujii ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Polycrystalline Diamond ◽  
Micro Milling ◽  
Grinding Wheels ◽  
Form Accuracy ◽  
Structured Surfaces ◽  
Milling Tool ◽  
Milling Tools

Micro milling tools made of PolyCrystalline Diamond (PCD) have been developed to machine ceramic micro dies and molds. Cutting edges are ground with diamond wheels. PCD milling tool wear is evaluated by cutting binder-less tungsten carbide spherical molds and machining structured surfaces for trial. Results of experiments clarified that PCD milling tool life is over 10 times that of resinoid diamond grinding wheels, and that form accuracy was 0.1 µm-0.3 µm P-V and surface roughness was 10 nm Rz.

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