Abstract
Surface quality is among the predominant criterion in measuring machining process performance, including milling. It is extremely dependent on the process variable, such as cutting parameters and cutting tool conditions. The main intention of this research work is to study the effect of the milling machining parameters, including depth of cut, spindle speed, feed rate as well as machining pattern to the final surface area roughness of the fabricated dimple structure. The concave profile of the dimple is machined at the right angle to a flat Al6061 specimen using a ball end mill attached to a 3-axis CNC milling machine, and the surface area of the concave profile is measured using 3D measuring laser microscope. It is observed that surface area roughness reacts with the spindle speed and feed rate with different tool sizes. Based on the result gained, the work has successfully characterised the influence of studied milling parameters on the dimple surface area roughness, where within the range of the studied parameter, the surface area roughness varies only less than 2.2 μm. The research work will be continued further on the incline milling technique and micro size ball end mill.
Highlights
The demand for micro features based machining has increased drastically due to technological advancement in various fields such as biomedical, orthopaedic implants, tribological applications, aerospace industry, automotive industry, sensory devices, electronics cooling devices, optics, and microfluidics [1][2][3]
This paper aims to study in depth the round dimple fabrication using low spindle speed range, as well as investigate the interaction of milling process parameters such as spindle speed and feed rate to the surface area roughness of the dimple structure
The main concern is to analyse the correlation between spindle speed, feed rate, tool size and pattern to the dimple surface area roughness
Summary
The demand for micro features based machining has increased drastically due to technological advancement in various fields such as biomedical, orthopaedic implants, tribological applications, aerospace industry, automotive industry, sensory devices, electronics cooling devices, optics, and microfluidics [1][2][3]. Micro features-based such as dimple, groove, and scale often applied to improve the performance of the part, especially in minimising wear and friction on sliding mechanical components [4][5]. The micro features-based are fabricated on the designated sliding surface to act as a lubricant reservoir as well as reducing contact area in-between during the surface in motions. Despite numbered fabrication processes, milling machining still considered a viable and flexible process at a lower cost. It is due to the capability to produce the micro dimple with a wide variety of materials, different types of dimple patterns, as well as micro profile itself such as dimple, groove and pyramid [7]
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