Hostname: page-component-cd9895bd7-dzt6s Total loading time: 0 Render date: 2024-12-24T14:12:48.614Z Has data issue: false hasContentIssue false
  • English
  • Français

Topography and Surface Roughness of Floor in Groove Micro Milling

Published online by Cambridge University Press:  21 October 2014

S. Kouravand ,
B. M. Imani  and
J. Ni
S. Kouravand
Affiliation:
Department of Agrotechnology, College of Abouraihan, University of Tehran, Tehran, Iran
B. M. Imani*
Affiliation:
Department of Mechanical Engineering, Ferdowsi University of Mashhad, Mashhad, Iran
J. Ni
Affiliation:
Department of Mechanical Engineering, University of Michigan, Ann Arbor, USA
*
*[email protected]
Get access

Abstract

Micro milling operation is a fabrication process to create 3D parts from tens of micrometers to a few millimeters in size using a tool with diameter less than 1mm. Micro groove is one of the common features observed in the micro parts. The surface roughness of micro grooves plays an important role in their performance. Since most of the finishing processes could not be easily performed on the micro grooves, it is of extreme importance to find a relationship between micro milling parameters and the surface roughness profile. In this paper, in order to anticipate the profile and surface roughness of the groove floor a model is proposed based on the kinematic of cutting process and tool geometry. The effects of minimum chip thickness, elastic recovery, size effect and tool deflection are included in the model. Relationship between position of points on the floor surface of groove and kinematics of cutting process are derived. In next step, simulations of proposed model are performed in the ACIS environment. Finally, using the DOE method surface roughness is investigated stochastically. The simulated and measured surface roughnesses are compared together that confirm the validity of proposed model.

Keywords

Micro millingSurface roughnessMinimum chip thicknessElastic recovery
Type
Research Article
Information
Journal of Mechanics , Volume 30 , Issue 6 , December 2014 , pp. 667 - 678
Copyright
Copyright © The Society of Theoretical and Applied Mechanics, R.O.C. 2014 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1.Chae, J., Park, S. S. and Freiheit, T., “Investigation of Micro-Cutting Operations,” International Journal of Machine Tools & Manufacture, 46, pp. 313–332 (2006).Google Scholar
2.Vogler, M. P., DeVor, R. E. and Kapoor, S. G., “On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part I: Surface Generation,” Journal of Manufacturing Science Engineering, 126, pp. 685–694 (2004).CrossRefGoogle Scholar
3.Malekian, M., Mostofa, M. G. and Park, S. S., “Modeling of Minimum Uncut Chip Thickness in Micro Machining of Aluminum,” Journal of Materials Processing, 212, pp. 553–559 (2012).CrossRefGoogle Scholar
4.Liu, X., DeVor, R. E. and Kapoor, S. G., “An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining,” Journal of Manufacturing Science Engineering, 128, pp. 474–481 (2006).Google Scholar
5.Weule, H., Huntrup, V. and Trischle, H., “Micro-Cutting of Steel to Meet New Requirements in Miniaturization,” CIRP Annals—Manufacturing Technology, 50, pp. 61–64 (2001).Google Scholar
6.Kim, C. J., Bono, M. and Ni, J., “Experimental Analysis of Chip Formation in Micro-Milling,” Transactions of the North American Manufacturing Research Institute of SME, 30, pp. 247–254 (2002).Google Scholar
7.Sun, Y., Liang, Y. and Du, R., “Simulation and Analysis of Surface Generation in Micro-milling,” Proceedings of the 6th WSEAS International Conference on Robotics, Control and Manufacturing Technology, pp. 30–35 (2006).Google Scholar
8.Liu, X., Jun, M., DeVor, R. E. and Kapoor, S. G, “Cutting Mechanisms and Their Influence on Dynamic Forces, Vibrations and Stability in Micro-Endmilling,” Proceedings of ASME International Mechanical Engineering Congress and RD&D Exposition, Anaheim, CA, US (2004).Google Scholar
9.Radzevich, S. P., Kinematic Geometry of Surface Machining, CRC Press, Boca Raton, Florida (2008).Google Scholar
10.de Lacalle, L. N. L., Lamikiz, A., S'anchez, J. A. and Salgado, M. A., “Effects of Tool Deflection in the High-Speed Milling of Inclined Surfaces,” International Journal of Advanced Manufacturing Technology, 24, pp. 621–631 (2004).Google Scholar
11.Kim, C. J., “Mechanisms of Chip Formation and Cutting Dynamics in The Micro-Scale Milling Process,” Ph.D. Dissertation, Department of Mechanical Engineering, University of Michigan, Michigan, US (2004).Google Scholar
12.Corney, J., 3D Modeling with the Acis Kernel and Toolkit, John Wiley, Chichester (1997).Google Scholar
13.Montgomery, C., Design and Analysis of Experiments, 4th Edition, Wiley, New York (1997).Google Scholar