Experimental analysis on the quality aspects of micro-channels in mechanical micro milling of Zr-based bulk metallic glass

Abstract

Amorphous metallic alloys possess important properties that are suitable for making micro-components used in several micro applications. Geometric accuracy in the shape and surface roughness of these micro components plays a vital role in their performance. In the present work, an experimental characterization of the quality aspects in the micro milling process is undertaken to assess the process capability in achieving the surface quality and the accuracy of the micro channels done on a workpiece made of bulk metallic glass. The influence of the cutting parameters on the quality aspects of the micro channels is investigated. The quality aspects analyzed are the average width of the micro channels and the surface roughness of the base of the micro channels. The results reveal that the average width of the micro-channels decreases with the increase in the axial depth of cut. For the chosen range of feed rates, higher feed rate shows better control towards the desired value. It is found that the effect of the feed per tooth on the roughness parameters is significant. In the present study it is observed that the surface roughness decreases with the decrease in the feed rate at values greater than the average cutting edge radius and reaches a minimum, and then tends to increase with further reduction in the feed rate. At very low feed rates the increase in the surface roughness values with the decrease in the feed rate is attributed to the material side flow that occurs at the secondary cutting edge.