Abstract
This paper presents an experimental research on surface roughness of fine-grained graphite machined by micro milling. POCO EDM-3 and POCO EDM-AF5 fine-grained graphite were adopted as workpiece material. A full groove milling was performed respectively using a tungsten carbide end mill with or without diamond-coating dedicated to graphite cutting. EDM-AF5, which has a smaller grain size than EDM-3, showed better property for surface roughness. The diamond-coated tool demonstrated more excellent abilities for micro milling than the uncoated tool, achieving more beautiful machining surface under higher cutting speed and feed rate condition. The influence degree of the grain size and the cutting parameters including cutting speed, feed rate and cutting depth on surface roughness was analyzed by using ANOVA method. The analysis results proved that the feed rate and the grain size have the most significant influence and the cutting depth only has a minor effect on the surface roughness, while the cutting speed is not an influence factor. Regression equations to predict the surface roughness value from related factors were derived with the regression analysis. Through additional verification experiments, the effectiveness of these equations was also confirmed.
Highlights
In recent years, the trend in reducing the size and increasing the integration level of various devices and products has significantly encouraged a development of metal processing for miniaturization and high precision [1] [2]
As can be seen from the values of the contribution ratio in the tables, it was confirmed that the grain size and the feed rate have a significant effect on the surface roughness, and the effect of the cutting depth was rather smaller
4.2 Results of the Regression Analysis Based on the analysis of variance (ANOVA) results mentioned above, the relationship between the arithmetical mean deviation of assessed profile, Ra(μ m), of workpiece surface and the influence factors is defined in the form of Eq (1)
Summary
The trend in reducing the size and increasing the integration level of various devices and products has significantly encouraged a development of metal processing for miniaturization and high precision [1] [2]. Micro electrical discharge machining (micro EDM) is a technology that gets a lot of attention for manufacture of miniature parts with complex 3D shape, especially suitable for accurate and efficient fabrication of micro dies, molds and tools made of difficult-to-machine materials in a small batch production [3] [4]. In such situation, it is an important core technique how to manufacture the electrodes for processing these micro parts with high precision and efficiency [5] [6].
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