Simulation and experiment study of burrs in micro-milling Zr-based metallic glass

Abstract

Metallic glass has been widely used in making micro parts and equipment due to its excellent physical and chemical performance. A large quantity of burrs is produced in the micro-milling process that is hard to remove and seriously affects the quality and precision of the parts. Burrs should be effectively restrained; however, the burrs’ type, position and the effect of milling parameters on burrs’ generation in micro-milling metallic glass have not been systematically studied. In this paper, by using 3-D FEM simulation and taking micro-milling experiments of Zr-based metallic glass (Vit1), the burrs in flat-end milling and ball-end milling micro grooves were investigated. The burrs’ type and position were observed and summarized, the formation process of various burrs was analyzed in detail, and the influence of cutting parameters on burrs was clarified. Comparing the simulation and experiment result, we could confirm that the top burr and the entrance burr were produced during the processing of the flat-end milling cutter, and ball-end milling cutter effectively inhibits the production of the top burr but takes no actions on burrs’ generation at the entrance and the bottom of the groove. The main cause of the top burr is the extrusion of the tool, and the extrusion of the cutting layer metal and chip accumulation were the main reason for entrance and exit burrs. Reducing the axial cutting depth could effectively restrain the generation of burrs for both two kinds of milling tools.