Abstract
Compared to milling on a macro scale, the micromilling process has several cumbersome points that need to be addressed. Rapid tool wear and fracture, severe burr formation, and poor surface quality are the major problems encountered in the micromilling process. This study aimed to reveal the effect of cutting path strategies on the cutting force and surface quality in the micromilling of a pocket. The hatch zigzag tool path strategy and the contour climb tool path strategy under different cooling conditions (e.g., dry, air blow, and flood coolant) at fixed cutting parameters. The micromilling tests revealed that better results were obtained with the use of the contour tool path strategy in terms of cutting forces (by up to ~43% compared to the dry condition) and surface quality (by up to ~44% compared to the air blow condition) when compared to the hatch tool path strategy. In addition, the flood coolant reduces the cutting temperature and eliminates chips to significantly enhance the quality of the micro milled surface.
Highlights
In the current era of manufacturing, there is a great demand for micro-scale devices and components which have complex features and are manufactured from many different materials [1].Micro-scale parts are utilized in a variety of fields, including the aerospace, automotive, medical, and precision die and mold manufacturing industries [2]
The results revealed that it was possible to obtain a high-quality surface roughness average Ra = 1.7 nm if the removed chips were sufficiently thin to carry out ductile mode machining
In contrast to the existing literature, this study aimed to investigate the effects of the cutting tool path strategy and cooling conditions on the cutting force and surface roughness of the AA 5083 H116 micro-milling of pocket geometry
Summary
In the current era of manufacturing, there is a great demand for micro-scale devices and components which have complex features and are manufactured from many different materials [1].Micro-scale parts are utilized in a variety of fields, including the aerospace, automotive, medical, and precision die and mold manufacturing industries [2]. In the current era of manufacturing, there is a great demand for micro-scale devices and components which have complex features and are manufactured from many different materials [1]. Micro machining is defined as the process of machining miniature parts using micro cutting tools. A number of studies have evaluated the performance of macro cutting tools in conventional machining by examining parameters such as the surface roughness, cutting force, tool wear, tool life, shape and dimensional errors, and computer aided manufacturing (CAM) stage in the high-speed milling of complex surfaces and parts [4,5,6,7,8,9,10,11]. The manufacturing of components from various materials via micro machining is, as yet, a more complex process than conventional machining. The high cutting force and temperature that occur during micro machining lead to problems such as sudden damage to the micro-tools
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