Abstract
Excessive tool wear during hard and brittle material processing severely influences cutting performance. As one of the advanced machining technologies, vibration-assisted micro milling adds high-frequency small amplitude vibration on a micro milling tool or workpiece to improve cutting performance, especially for hard and brittle materials. In this paper, the tool wear suppression mechanism in non-resonant vibration-assisted micro milling is studied by using both finite element simulation and experiment methods. A finite element model of vibration-assisted micro milling using ABAQUS is developed based on the Johnson cook material and damage models. The tool-workpiece separation conditions are studied by considering the tool tip trajectories. The machining experiments are carried out on Ti-6Al-4V with a coated micro milling tool (fine-grain tungsten carbide substrate with ZrO2-BaCrO4 (ZB) coating) under different vibration frequencies (high, medium, and low) and cutting states (tool-workpiece separation or non-separation). The results show that tool wear can be reduced effectively in vibration-assisted micro milling due to different wear suppression mechanisms. The relationship between tool wear and cutting performance is studied, and the results indicate that besides tool wear reduction, better surface finish, lower burrs, and smaller chips can also be obtained as vibration assistance is added.
Highlights
Many industrial sections have been striving towards product miniaturization
It has been reported that the ratio of uncut chip thickness to cutting edge radius is closely linked with the machining surface ploughing effect, effective rake angle, and specific cutting energy, which in turn impacts the cutting performance [4,5,6]
The results show that the tool wear can be reduced effectively when the tool-workpiece separation occurs, as well as a higher applied vibration frequency
Summary
Many industrial sections have been striving towards product miniaturization. In order to obtain superior physical, mechanical, optical, and electronic properties, hard and brittle materials, such as titanium alloy, silicon carbide ceramic, and optical glass, have been chosen for micro products, e.g., medical devices, bio-sensors, micro-fluidic chips, to name a few [1,2]. It has been reported that the ratio of uncut chip thickness to cutting edge radius is closely linked with the machining surface ploughing effect, effective rake angle, and specific cutting energy, which in turn impacts the cutting performance [4,5,6] When it refers to hard and brittle materials, low fracture toughness and often poor thermal conductivity make processing these materials a challenging task. Li et al [20] investigated the vibration-assisted micro milling process and found that the tool life is extended compared with conventional milling results and better surface roughness and lower burrs can be obtained because it reduces the secondary damage of the worn cutting tool to the machined surface effectively. Better surface finish, lower burrs, and smaller chips can be found when vibration assistance is added
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