scholarly journals Investigation on the Exit Burr Formation in Micro Milling

Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 952
Author(s):  
Zhongwei Chen ◽  
Xian Wu ◽  
Kai Zeng ◽  
Jianyun Shen ◽  
Feng Jiang ◽  
...  
Keyword(s):  
Control Strategies ◽  
Harmful Effect ◽  
Dimensional Accuracy ◽  
Micro Milling ◽  
Burr Formation ◽  
Machining Parameters ◽  
Exit Surface ◽  
Exit Burr ◽  
Machining Parameter ◽  
Cutting Direction

The burr on micro part has harmful effect on the dimensional accuracy and service performance. The original control of exit burr formation during micro milling is desirable and advisable. In this paper, the formation mechanism of exit burr was studied based on the varying cutting direction during micro milling. Three exit burr control strategies were concluded, the material properties embrittlement, the support stiffness increasing and machining parameter optimizing operations. Then, micro milling experiments were carried out to investigate the exit burr morphology and size. It was found that the exit burr formation was attributed to the change of material flowing path at the exit surface, which was caused by the negative shear deformation zone that was induced by the discontinuous shape features. Different exit burr morphologies were classified; the triangle exit burr type was caused by the varying exit burr growing direction along the exit surface. The optimal machining parameters in micro milling to obtain a small exit burr were suggested.

The Effect of Machining Toolpath on Surface Roughness and Dimensional Accuracy for High-Speed Micro Milling

2017 ◽  
Vol 261 ◽  
pp. 69-76
Author(s):  
Amin Dadgari ◽  
De Hong Huo ◽  
David Swailes
Keyword(s):  
Surface Roughness ◽  
Process Planning ◽  
Tool Path ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Micro Milling ◽  
Geometric Features ◽  
Machining Parameters ◽  
Machining Performance ◽  
Planning Stage

This paper investigates different machining toolpath strategies on machining efficiency and accuracy in the micro milling of linear and circular micro geometric features. Although micro milling includes many characteristics of the conventional machining process, detrimental size effect in downscaling of the process can lead to excessive tool wear and machining instability, which would, in turn, affects the geometrical accuracy and surface roughness. Most of the research in micro milling reported in literature focused on optimising specific machining parameters, such as feed rate and depth of cut, to achieve lower cutting force, better surface roughness, and higher material removal rate. However, there was little attention given to the suitability and effect of machining tool path strategies. In this research, a tool path optimisation method with respect to surface roughness and dimensional accuracy is proposed and tested experimentally. Various toolpath strategies, including lace(0°), lace(45°), lace(90°), concentric and waveform in producing linear and circular micro geometric features were compared and analysed. Experimental results show that the most common used strategies lace(0°) and concentric reported in the literature have provided the least satisfactory machining performance, while waveform toolpath provides the best balance of machining performance for both linear and circular geometries. Hence, at process planning stage it is critical to assign a suitable machining toolpath strategy to geometries accordingly. The paper concludes that an optimal choice of machining strategies in process planning is as important as balancing machining parameters to achieve desired machining performance.

Research on the Modeling and Experimenting of Burr Formation Process in Double-Edged Micro-Plat End Milling Operation

2013 ◽  
Vol 770 ◽  
pp. 248-252 ◽  
Author(s):  
Ni Chen ◽  
Ming Jun Chen ◽  
Hai Bo Ni ◽  
Ning He ◽  
Zhan Qiang Liu
Keyword(s):  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Generation Process ◽  
Burr Size ◽  
Milling Operation ◽  
Exit Burr

Burrs generated in micro-milling operation have a significant impact on the surface quality and operational performance of the finished microstructures. In order to gain a better recognition of burr generation process, 3-dimensional double-edged micro-flat end milling operation FEM models on Ti6Al4V have been established. Burrs occurred in simulation can be classified into three types: entrance burr, exit burr, top burr. Their formation processes and causes are well investigated and analyzed, moreover, a series of experiments are conducted to validate the burr morphologies which are received in simulation. At last, the effect of cutting parameters on top burr size is studied through orthogonal experiment on Ti6Al4V, it can be concluded that the axial depth of cut has the greatest effect on top burr size, and the effect of spindle speed on top burr size is the least.

Multi-Objective Optimization for the Micro-Milling Process With Adaptive Data Modeling

2011 ◽  
Author(s):  
Xinyu Liu ◽  
Weihang Zhu ◽  
Victor Zaloom
Keyword(s):  
Surrogate Model ◽  
Data Modeling ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Optimization Study ◽  
Machining Parameter

This paper presents a multi-objective optimization study for the micro-milling process with adaptive data modeling based on the process simulation. A micro-milling machining process model was developed and verified through our previous study. Based on the model, a set of simulation data was generated from a factorial design. The data was converted into a surrogate model with adaptive data modeling method. The model has three input variables: axial depth of cut, feed rate and spindle speed. It has two conflictive objectives: minimization of surface location error (which affects surface accuracy) and minimization of total tooling cost. The surrogate model is used in a multi-objective optimization study to obtain the Pareto optimal sets of machining parameters. The visual display of the non-dominated solution frontier allows an engineer to select a preferred machining parameter in order to get a lowest cost solution given the requirement from tolerance and accuracy. The contribution of this study is to provide a streamlined methodology to identify the preferred best machining parameters for micro-milling.

Effect of In-Plane Exit Angle and Rake Angles on Burr Height and Thickness in Face Milling Operation

1999 ◽  
Vol 121 (1) ◽  
pp. 13-19 ◽  
Author(s):  
M. Hashimura ◽  
J. Hassamontr ◽  
D. A. Dornfeld
Keyword(s):  
Three Dimensional ◽  
Rake Angle ◽  
Burr Formation ◽  
Formation Mechanisms ◽  
304L Stainless Steel ◽  
Exit Angle ◽  
Dimensional Effects ◽  
Exit Surface ◽  
Radial Rake Angle ◽  
Exit Burr

Burrs formed by milling are three-dimensional in nature. Therefore the three-dimensional effects on milling burr formation in 304L stainless steel were considered. An important aspect of the three-dimensional effects is the exit order of the tool edges because the burr remains near the final exit position of the tool along the workpiece edge. The geometric parameters of the workpiece and tools were varied to change exit order in the workpiece around the cutting edge. Moreover in this paper, classification of milling burrs based on burr location, shape and mechanism is also proposed to avoid confusion. The milling burrs were classified according to three locations, five shapes and four burr formation mechanisms based on fractography. The exit burr on the exit surface and the side burr on transition surface of workpiece were mainly analyzed. The effect of in-plane exit angle and radial rake angle on burr formation were shown and the burr formation mechanism for each burr was also discussed.

Study of Machining Parameter Optimization in Drilling of Magnesium Based Hybrid Composites Reinforced with SiC/CNT

2020 ◽  
Vol 846 ◽  
pp. 42-46 ◽  
Author(s):  
J.S.Suresh Babu ◽  
Min Heo ◽  
Chung Gil Kang
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hybrid Composites ◽  
Spindle Speed ◽  
Influential Factor ◽  
Burr Formation ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Wide Range ◽  
Machining Parameter

Recently, researchers and engineers have been interested in the development of hybrid metal matrix composites (HMMCs) for the applications of automotive and aerospace industries owing to their superior properties due to the usage a wide range of material combinations in its manufacturing. The present study focuses on the machining of magnesium based hybrid composites reinforced with CNT (1vol.%) and SiC (2vol.%).The influence of machining parameters such as spindle speed, feed rate, drill diameter and point angle on burr formation and surface roughness on drilling the composites were investigated using Taguchi method. The drilling parameters were optimized by using ANOVA experimental design and also find out the percentage of contribution of each factor. Based on the results, the most influential factor for the burr thickness was spindle speed and point angle. While spindle speed and feed rate were the influencing factors for surface roughness. The analysis revealed that burr height, burr thickness, and surface roughness decreases significantly with an increase in spindle speed.

Experimental investigation and processing optimization for micro-milling of copper clad polyimide

2016 ◽  
Vol 232 (4) ◽  
pp. 670-680 ◽  
Author(s):  
Kai Zhao ◽  
Zhenyuan Jia ◽  
Yuanyuan Gao ◽  
Lichao Ding
Keyword(s):  
Three Dimensional ◽  
Processing Parameters ◽  
Raw Material ◽  
Micro Milling ◽  
Burr Formation ◽  
Machining Parameters ◽  
Burr Height ◽  
Processing Optimization ◽  
Traditional Processing ◽  
Tool Diameter

Copper clad polyimide is becoming a significant raw material for the manufacturing of special circuits such as antennas. Micro-milling, which provides a direct and flexible fabrication method in three-dimensional product machining, has replaced traditional processing methods such as photolithography. However, severe burr problem which leads to serious power loss due to the skin effect is encountered because of the selection of improper machining strategies and parameters. In this study, the influence of machining strategy on burr formation is investigated at first. Then, the formation mechanism for different kinds of burrs in micro-milling of copper clad polyimide is analyzed. Furthermore, the burr height prediction model is established, and the optimized processing parameters are obtained through response surface methodology, the predicted burr height is 12 µm. At last, a verification experiment is conducted with the optimized processing parameters. The machining result shows that the optimized parameter combination contains spindle speed of 36,110 r/min, feed per tooth of 0.70 µm/z and tool diameter of 200 µm. The average burr height for verification test is 13.9 µm. Because of the instability of copper layer on copper clad polyimide, the actual burr height is slightly larger than theoretical prediction. The error between predicted value and experiment value is 15.8%. What is noticeable is that before optimization, the burr height is up to 100 µm, while after optimization, it reduces to 13.9 µm which is reduced by 86.1%. The achievements in this study are of great significance for optimizing machining parameters and improving machining quality and efficiency of copper clad polyimide, especially in antennas field.

Study on Burr Formation in Face Milling of Stainless Steel with Chamfered Cutting Tool

2008 ◽  
Vol 53-54 ◽  
pp. 83-88 ◽  
Author(s):  
Lu Lu Jing ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Stainless Steel ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Face Milling ◽  
Cutting Edge ◽  
Burr Formation ◽  
Maximum Height ◽  
Machining Parameters ◽  
Burr Size ◽  
Exit Burr

Due to the properties such as high strength and high toughness, burr was commonly produced in the machining of stainless steel 1Cr18Ni9Ti, especially when a chamfered cutting tool was used. This study investigated the effects of chamfering geometry of cutting edge and machining parameters on burr formation and presented active control methods to minimize burr size on the exit end based on the experimental research in milling of 1Cr18Ni9Ti. Experiments of face milling with various cutting edge geometric features were conducted. Maximum height and thickness of exit burr and exit side burr were measured. As a result, a proper chamfering geometry that combined the advantages of enhancing the cutting edge strength and obtaining favorable burr types was presented. The experimental results also showed that a relatively high cutting speed was helpful in reducing burr formation; proper medium feed rate and axial depth were favorable for the minimization of burr size. This research is beneficial for precise machining of stainless steel.

Research of Micro Burr in Miniaturized Milling Process

2012 ◽  
Vol 566 ◽  
pp. 612-615 ◽  
Author(s):  
Zi Yang Cao ◽  
Hua Li
Keyword(s):  
Machine Tool ◽  
Three Dimensional ◽  
Influence Factors ◽  
Tool Material ◽  
Milling Process ◽  
Micro Milling ◽  
Burr Formation ◽  
Machining Parameters ◽  
Milling Machine ◽  
Milling Characteristics

The milling characteristics experiments with typical micro three dimensional parts are done by the developed 3-axis micro-milling machine tool, and the micro burr formed in micro-milling process is observed and analyzed. Burr formation and its influence factors in micro-milling process are studied and general influencing rule of each factor to burr formation is summarized. Based on the results, the purpose to reduce the burr is achieved through choosing proper machining parameters and tool material.

scholarly journals Multi-Criteria Selection of the Optimal Parameters for High-Speed Machining of Aluminum Alloy Al7075 Thin-Walled Parts

Metals ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1570
Author(s):  
Dejan Lukic ◽  
Robert Cep ◽  
Jovan Vukman ◽  
Aco Antic ◽  
Mica Djurdjev ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Tool Path ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Optimal Level ◽  
Machining Parameters ◽  
Thin Walled ◽  
Machining Parameter ◽  
Selection Of

Thin-walled parts made of aluminum alloy are mostly used as structural elements in the aerospace, automobile, and military industries due to good homogeneity, corrosion resistance, and the excellent ratio between mechanical properties and mass. Manufacturing of these parts is mainly performed by removing a large volume of material, so it is necessary to choose quality machining parameters that will achieve high productivity and satisfactory quality and accuracy of machining. Using the Taguchi methodology, an experimental plan is created and realized. Based on its results and comparative analysis of multi-criteria decision making (MCDM) methods, optimal levels of machining parameters in high-speed milling of thin-walled parts made of aluminum alloy Al7075 are selected. The varying input parameters are wall thickness, cutting parameters, and tool path strategies. The output parameters are productivity, surface quality, dimensional accuracy, the accuracy of forms and surface position, representing the optimization criteria. Selection of the optimal machining parameter levels and their ranking is realized using 14 MCDM methods. Afterward, the obtained results are compared using correlation analysis. At the output, integrative decisions were made on selecting the optimal level and rank of alternative levels of machining parameters.

Development of vibration-assisted micro-milling device and effect of vibration parameters on surface quality and exit-burr

2018 ◽  
Vol 233 (6) ◽  
pp. 1723-1729 ◽  
Author(s):  
Guo Li ◽  
Bo Wang ◽  
Jiadai Xue ◽  
Da Qu ◽  
Peng Zhang
Keyword(s):  
Surface Roughness ◽  
Vibration Frequency ◽  
Prediction Interval ◽  
Micro Milling ◽  
Machining Parameters ◽  
Burr Size ◽  
Cubic Polynomial ◽  
The Mean ◽  
Vibration Parameters ◽  
Exit Burr

Vibration-assisted cutting is an important technology with better performance in manufacturing micro-scaled components, compared with conventional cutting technology. This article first illustrates the development of vibration-assisted micro-milling device which is made based on piezoelectric plates and shows different vibration types with vibration principle of this device. It is then tested stable to output vibration with a frequency accuracy of 100 Hz and an amplitude accuracy of 100 nm. Two groups of experiments in micro-milling 6061 aluminum alloy are carried out. Compared with conventional micro-milling, using vibration assist is verified more effective in improving surface integrity and quality. Furthermore, with a proposed method of characterizing exit-burr size, the influences of vibration frequency and amplitude on surface roughness and exit-burr size are discussed. As a result, the mean surface roughness is found positive related to vibration frequency and negative related to vibration amplitude in most of the study range. To make guidance on optimizing vibration machining parameters, cubic polynomial fitting with 95% prediction interval is of enough accuracy.

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