An experimental investigation on the formation of burrs in micro milling of Zr-based amorphous bulk metallic glass

Abstract

Fabrication of precision micro components demands part quality having burr free edges and acceptable surface finish to comply with its requirements of proper functionality. Machining conditions influence process performances in different ways. The present study examines the effect of cutting parameters like cutting speed, feed per tooth (feed rate) and axial depth of cut on the formation of top burrs and surface finish produced in micro-channels made through full immersion micro end milling process carried out on a workpiece made of amorphous bulk metallic glass (BMG). The process modelling is done based on response surface methodology and parametric analysis is performed to examine the influence of the process parameters on the process responses, namely the burr size formed in up-milling and down-milling sides and the surface roughness of the bottom surface of the micro-channels. The study also undertakes multiple response optimisation analysis that determines the optimal values of the cutting parameters that yield lower burr sizes and lower surface roughness.