scholarly journals Simulation-Based and Experimental Investigation of Micro End Mills with Wiper Geometry

Micromachines ◽  
2021 ◽  
Vol 12 (5) ◽  
pp. 496
Author(s):  
Timo Platt ◽  
Alexander Meijer ◽  
Torben Merhofe ◽  
Dirk Biermann
Keyword(s):  
Surface Topography ◽  
Cutting Parameters ◽  
High Agreement ◽  
Residual Stress State ◽  
Compressive Stresses ◽  
Simulation Based ◽  
Solid Carbide ◽  
End Mills ◽  
Steel Aisi ◽  
Milling Tools

One of the major advantages of micromachining is the high achievable surface quality at highly flexible capabilities in terms of the machining of workpieces with complex geometric properties. Unfortunately, finishing operations often result in extensive process times due to the dependency of the resulting surface topography on the cutting parameter, e.g., the feed per tooth, fz. To overcome this dependency, special tool shapes, called wipers, have proven themselves in the field of turning. This paper presents the transfer of such tool shapes to solid carbide milling tools for micromachining. In this context, a material removal simulation (MRS) was used to investigate promising wiper geometries for micro end mills (d = 1 mm). Through experimental validation of the results, the surface topography, the resulting process forces, and tendencies in the residual stress state were investigated, machining the hot work tool steel (AISI H11). The surface-related results show a high agreement and thus the potential of MRS for tool development. Deviations from the experimental data for large wipers could be attributed to the non-modeled tool deflections, friction, and plastic deformations. Furthermore, a slight geometry-dependent increase in cutting forces and compressive stresses were observed, while a significant reduction in roughness up to 84% and favorable topography conditions were achieved by adjusting wipers and cutting parameters.

Cutting Forces in High Speed Milling of Hardened Steel by Coated Tool

2009 ◽  
Vol 69-70 ◽  
pp. 418-422
Author(s):  
L.D. Wu ◽  
Cheng Yong Wang ◽  
D.H. Yu ◽  
Yue Xian Song
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Coated Tool ◽  
Radial Depth ◽  
Solid Carbide ◽  
End Mills

Hardened steel P20 at 50 HRC is milled at high speed by TiN coated and TiAlN coated solid carbide straight end mills, and the cutting forces and tool wear are measured. The result shows that TiAlN coated tool is more suitable for cutting hardened steel at high speed. Then the hardened steel is milled under different cutting parameters. It is indicated that the effect of cutting speed on cutting forces is small, but the effect of cutting speed on machine vibration should be considered. Increase feed per tooth or radial depth of cut will increase the cutting forces.

scholarly journals Analysis of Abrasives On Cutting Edge Preparation By Drag Finishing

2021 ◽  
Author(s):  
Dejin Lv ◽  
Yongguo Wang ◽  
Xin Yu ◽  
Han Chen ◽  
Yuan Gao
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Material Removal ◽  
Cutting Edge ◽  
K Factor ◽  
Solid Carbide ◽  
End Mills ◽  
Cutting Edge Preparation ◽  
Drag Finishing ◽  
Edge Preparation

Abstract Cutting edge preparation has become more important for tool performance. The micro-shape, radius and surface topography of the cutting edge plays a significant role in the machining process. The cutting edge of solid carbide end mills have some micro-defects after grinding. For eliminating aforementioned problem, this study investigates drag finishing (DF) preparation for solid carbide end mills reconstruct cutting edge micro-geometry. This paper is to present the design of DF experimental set-up and analysis the characterization of various abrasive media (K3/600, K3/400, HSC 1/300 and HSO 1/100) on the evolution of the surface /roughness along the cutting edge. In parallel, the mechanism of material removal and the kinematics trajectory of the drag finishing are presented. In fact, the form factor (also called as “K-factor”) of the cutting edge micro-geometry is quantified. Comparing with four lapping media, the higher material removal rate (MRR) and the lower surface roughness are obtained by HSO 1/100 abrasive process. The results show that the cutting edge K-factor, MRR and surface topography are influenced by the abrasive particles size, composition and process time. The cutting edge micro-geometry is measured through Scanning Electron Microscopy (SEM) and 3D Optical measuring instrument.

scholarly journals Effect of Machining Parameter and Multi-Response Optimization during End-Milling in GFRP-VARTM Composites using RSM Based Response Surface Regression Method

2019 ◽  
Vol 8 (4) ◽  
pp. 7180-7182
Keyword(s):  
Response Surface ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Machining Parameters ◽  
Solid Carbide ◽  
End Mills ◽  
Glass Fiber Reinforcement ◽  
Response Surface Regression ◽  
Machining Parameter

This paper is going to find out the correlation between cutting parameters and responses for GFRP composite material during end milling using the WC-CO tool. An experimental plan, based on Response Surface Methodology (RSM) techniques according to the Response Surface Regression (RSR), made up of Vaccum-Assisted Resin Transfer molding using solid carbide end mills. The objective of this paper is to investigate the machining parameters on glass fiber reinforcement polymer during the end milling process of a WC-Co cutting tool grade.

scholarly journals Influence of End Mill Manufacturing on Cutting Edge Quality and Wear Behavior

2021 ◽  
Vol 5 (3) ◽  
pp. 77
Author(s):  
Berend Denkena ◽  
Alexander Krödel-Worbes ◽  
Sascha Beblein ◽  
Markus Hein
Keyword(s):  
Wear Behavior ◽  
Cutting Edge ◽  
End Mills ◽  
Edge Quality ◽  
Manufacturing Process Chain ◽  
The Individual ◽  
Application Specific ◽  
Milling Tools ◽  
Edge Preparation

One of the decisive factors for the performance of milling tools is the quality of the cutting edge. The latter results from the process control of the individual steps along the tool manufacturing process chain, which generally includes the sintering or pressing of the blanks, grinding, cutting edge preparation, and coating of the tools. However, the targeted and application-specific design of the process steps in terms of high economic efficiency is currently limited by a lack of knowledge regarding the influence of the corresponding process parameters on the resulting cutting edge quality. In addition, there is a lack of suitable parameters that adequately represent the characteristics of the cutting edge microtopography. This publication therefore investigates the influence of manufacturing processes on cutting edge quality and wear behavior of end mills. On this basis, different characterization parameters for the cutting edge quality are derived and evaluated with regard to their ability to predict the wear behavior.

scholarly journals Microstructure and Properties of the AlCrSi(O)N Tool Coatings by Arc Ion Plating

Coatings ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 841
Author(s):  
Yanmei Liu ◽  
Tie-Gang Wang ◽  
Wei Lin ◽  
Qiang Zhu ◽  
Bing Yan ◽  
...  
Keyword(s):  
Cutting Tools ◽  
Medium Carbon Steel ◽  
Arc Ion Plating ◽  
Ion Plating ◽  
Mechanical And Tribological Properties ◽  
Hardness Tester ◽  
Coated Tool ◽  
Solid Carbide ◽  
End Mills ◽  
Coating Design

Aluminum rich nitride coatings are often used to protect cutting tools and prolong their service life. In this work, a preoxidation technique and duplex coating design were combined to further improve the bearing capacity and heat resistance of cutting tools. The Al-Cr-Si-N, Al-Cr-Si-O-N, and Al-Cr-Si-N/Al-Cr-Si-O-N duplex coatings were developed by arc ion plating, respectively. The morphology, phase constituents, mechanical and tribological properties of the coatings were characterized and tested by SEM, XRD, a micro-hardness tester, scratch tester, and tribometer. The results showed the coating became more compact and smoother after oxygen doping. However, the Al-Cr-Si-N coating presented the best mechanical properties and tribological behaviors. Its hardness and critical load showed the highest values, which were about 4000 HV and 81 N, respectively. A friction coefficient of 0.67 and wear rate of 1.4 × 10−3 μm3/N·mm were also the lowest values in the study. The three coatings were deposited on the same solid carbide end mills and performed the cutting tests under same conditions. By comparison, the Al-Cr-Si-N coated tool presented the longest tool life and minimum cutting force when cutting C1045 medium-carbon steel. After 90 min of dry milling, the width of the flank wear band (VB) of the AlCrSiN coated tool reached 135 μm, which was much lower than that of the other two coated tools.

scholarly journals Effect of Al2O3 Sandblasting Particle Size on the Surface Topography and Residual Compressive Stresses of Three Different Dental Zirconia Grades

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 610
Author(s):  
Hee-Kyung Kim ◽  
Byungmin Ahn
Keyword(s):  
Particle Size ◽  
Residual Stresses ◽  
Surface Topography ◽  
Tetragonal Zirconia ◽  
Peak Shift ◽  
Confocal Laser ◽  
Compressive Stresses ◽  
Surface Topographies ◽  
Altered Surface ◽  
Tetragonal Zirconia Polycrystal

This study investigated the effect of sandblasting particle size on the surface topography and compressive stresses of conventional zirconia (3 mol% yttria-stabilized tetragonal zirconia polycrystal; 3Y-TZP) and two highly translucent zirconia (4 or 5 mol% partially stabilized zirconia; 4Y-PSZ or 5Y-PSZ). Plate-shaped zirconia specimens (14.0 × 14.0 × 1.0 mm3, n = 60 for each grade) were sandblasted using different Al2O3 sizes (25, 50, 90, 110, and 125 μm) under 0.2 MPa for 10 s/cm2 at a 10 mm distance and a 90° angle. The surface topography was characterized using a 3-D confocal laser microscopy and inspected with a scanning electron microscope. To assess residual stresses, the tetragonal peak shift at 147 cm−1 was traced using micro-Raman spectroscopy. Al2O3 sandblasting altered surface topographies (p < 0.05), although highly translucent zirconia showed more pronounced changes compared to conventional zirconia. 5Y-PSZ abraded with 110 μm sand showed the highest Sa value (0.76 ± 0.12 μm). Larger particle induced more compressive stresses for 3Y-TZP (p < 0.05), while only 25 μm sand induced residual stresses for 5Y-PSZ. Al2O3 sandblasting with 110 μm sand for 3Y-TZP, 90 μm sand for 4Y-PSZ, and 25 μm sand for 5Y-PSZ were considered as the recommended blasting conditions.

A New Approach for a Simulation-Based Prediction of Torsional Chatter in Deep Hole Drilling With Extra-Long Twist Drills

2013 ◽  
Author(s):  
E. Abele ◽  
D. Schäfer
Keyword(s):  
General Structure ◽  
Cutting Parameters ◽  
Torsional Stiffness ◽  
Hole Drilling ◽  
New Approach ◽  
Process Dynamics ◽  
Chatter Vibrations ◽  
Simulation Based ◽  
High Level ◽  
Twist Drills

Numerous investigations work on torsional chatter vibrations in drilling. Particularly in terms of productivity, torsional chatter is detrimental because of a reduction of tool life and an undesirably high level of noise emissions due to the increased process dynamics. To achieve a deeper understanding of the process dynamics, a new numerical simulation model was developed to predict torsional chatter for extra-long twist drills. It is used to determine the influence of numerous factors such as cutting parameters, drill torsional stiffness, rotary moment of inertia and torsional-axial coupling. In this paper, the general structure of the model and the tool model is presented.

Comparative Analysis on Wiper and Standard Tools in Dry Finish Turning of Martensitic Stainless Steel AISI 420

2013 ◽  
Vol 845 ◽  
pp. 765-769 ◽  
Author(s):  
Guilherme Cortelini Rosa ◽  
André J. Souza ◽  
Flávio J. Lorini
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Residual Stresses ◽  
Martensitic Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Finish Turning ◽  
Aisi 420 ◽  
Steel Aisi ◽  
Stainless Steel Aisi

Machining performance consists to associate the optimal process and cutting parameters and maximum material removal rate with the most appropriate tool while controlling the machined surface state. This work verifies the influence of standard and wiper cutting tools on generated surface roughness and residual stress in dry finish turning operation of the martensitic stainless steel AISI 420 in a comparative way. Tests are conducted for different combinations of tool nose geometry, feed rate and depth of cut being analyzed through the Design of Experiments regarding to surface roughness parametersRaandRt. Moreover, the formation of residual stresses in the material (using the technique of X-Ray Diffraction) was evaluated after the machining process for these two cutting geometries and thereafter the result was compared between them. An ANOVA is performed to clarify the influence of cutting parameters on generated surface roughness, which outputs inform that cutting tool geometry is the most influent onRaandRt. It is concluded that analyzed wiper inserts present low performance for low feed rates. Regarding the analysis of the residual stresses it can be stated that for standard and wiper tools the values collected show that for finish turning the compression stresses were found. It can be observed that the greatest amount of compressive stress has been found for the standard tool.

The Investigation of a Micro-Component Machined on a Custom-built Miniature Machine Tool

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Syaimak Abdul Shukor
Keyword(s):  
Surface Quality ◽  
Milling Process ◽  
Micro Milling ◽  
Batch Size ◽  
Geometrical Accuracy ◽  
Custom Made ◽  
Micro Parts ◽  
Solid Carbide ◽  
Steel Aisi

Custom-built Miniature Machine Tools (MMTs) are now becoming more popular with the demand for reduced energy consumption and workshop floor when machining small/medium batch size micro-components. This paper investigates the capability of a custom-built 4-axis MMT through machining an “adapted standard‟ of micro-testpiece. The experiments have been carried out in two different materials: Carbon Steel (AISI 1040) and Titanium Alloyed (TiAl6V4) using solid carbide flat end mill cutters with 0.6mm diameter. From here, the surface quality and geometrical accuracy of the machined testpiece are evaluated and analysed. The investigation has shown that acceptable geometrical accuracies and surface quality of the machined micro-parts can be achieved using the in-house developed MMT. These results show that the use of the custom-made MMT does not hinder the micro-milling process to produce a good and satisfactory surface quality (Ra=0.04-0.07μm) and acceptable geometrical accuracy.

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