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DLC Coating in Cutting Tools
Published in Peerawatt Nunthavarawong, Sanjay Mavinkere Rangappa, Suchart Siengchin, Kuniaki Dohda, Diamond-Like Carbon Coatings, 2023
J. Noshiro, S. Ueda, T. Funazuka, Kuniaki Dohda
Figure 10.14 shows the comparison of workpiece machining conditions between the DLC end mill and the untreated carbide end mill when dry machining rolled aluminum alloy A5052 with a 2-flute end mill of φ10 mm. The machining conditions were as follows: 628 m/min cutting speed, 0.05 mm/tooth feed rate: 15 mm depth of cut (DOC), 2.5 mm width of cut (WOF). In contrast to the untreated carbide endmill, the workpiece was welded to the endmill and broke immediately after the start of cutting, and the DLC endmill in Figure 9.14(a) was able to perform two operations as shown in Figure 9.14(b). Figure 10.15 shows the results of measuring the surface roughness of the finished surface of the workpiece after machining. The surface roughness of the finished surface of the DLC end mill was 1/6 of that of the untreated carbide end mill, which is a very small value. This is presumably because the DLC coating reduced the deposition of aluminum on the tool cutting edge and reduced the generation and detachment of the component cutting edge. The result shows that it is also possible to improve the cutting accuracy.
Techniques for Applying SMED
Published in Shigeo Shingo, Andrew P. Dillon, A Revolution in Manufacturing: The SMED System, 2019
Shigeo Shingo, Andrew P. Dillon
Several improvements were made: The height of the milling machine table was fixed and the distance to the endmill blade was set at 120 mm.The dimensions of the various bodies and jigs were determined. Contact jigs compensating for height were mounted and set on the table so that the cutting surface would be 120 mm.The horizontal and vertical dimensions of the contact jigs were standardized. By pushing them up against stoppers set into the table, workers could easily center the body.
Fabrication of functionally graded bio materials by Nano Composite Deposition System
Published in Paulo Jorge Bártolo, Artur Jorge Mateus, Fernando da Conceição Batista, Henrique Amorim Almeida, João Manuel Matias, Joel Correia Vasco, Jorge Brites Gaspar, Mário António Correia, Nuno Carpinteiro André, Nuno Fernandes Alves, Paulo Parente Novo, Pedro Gonçalves Martinho, Rui Adriano Carvalho, Virtual and Rapid Manufacturing, 2007
H.-J. Kim, W.-S. Chu, S.-H. Ahn, C.S. Lee
A hemispherical part with a diameter 5.0 mm was fabricated to compare the precision of deposition only and hybrid (deposition + micro milling) processes. The deposition was done by a dispensing process using a ϕ 250 µm needle, and micro milling using a ϕ 300 µm ball endmill was applied for the hybrid process (Fig. 12).
Observation of Non-Taylorian tool wear and machining parameter selection for miniature milling of Ti-6Al-4V on regular CNC machines
Published in Australian Journal of Mechanical Engineering, 2022
Abhijit Bhattacharyya, Scott W. T. Payne, John. K. Schueller
Previous researchers (Uhlmann and Schauer 2005; Bao and Tansel 2000) who have conducted extensive experiments on microendmilling of steels, using solid carbide endmills of the type used in the current research, have been careful to limit the total cutting force to 50 N. (Bao and Tansel 2000) have presented an experimental result where the increase in cutting force on a 1/16 (1.5875 mm) diameter endmill running at a feed of 0.017 mm/tooth was monitored. The endmill experienced abrasive wear cutting graphite. Cutting force increased from 13 N to 35 N as the tool wear progressed, i.e. the cutting force increased 270%. Such drastic increase in cutting forces were observed by them in other micromilling applications such as machining steel with carbide micromills. Increase in cutting forces due to tool wear must be planned for when deciding the feed rate to be chosen for the operation. Using the conventional force model, it was found that corresponding to a feed of 0.010 mm/tooth, an axial depth of cut of 0.5 mm, and a 10% radial immersion, the total cutting force was below 10 N, as seen in Figure 1(b), which provides a comfortable safety cushion to account for increased cutting forces as tool wear evolves.
Micro-structure evolution-based force model and surface characteristic studies of Inconel 718 during micro-endmilling
Published in Machining Science and Technology, 2021
N. Anand Krishnan, K. Vipindas, Jose Mathew
Tungsten carbide endmill with AlTiN coating, 500 µm cutter diameter, 10° clearance angle and 8° rake angle were used in this research. As the edge radius of endmill cutter has a critical role on the size effect in micro-endmilling, it was measured using the 3D optical profilometer. Figure 5 shows the optical micrographs of the micro-endmill and edge radius measurement. From Figure 5, it was found that the cutter edge radius was adjacent to 3 µm.
Virtual design and machining of core and cavity for fabrication of dining plate tableware with Kawung batik pattern
Published in Cogent Engineering, 2022
P.W. Anggoro, M.B. Krishnayuda, T. Yuniarto, B. Bawono, Y. Suharyanti, S. Felasari, D.B. Setyohadi, O.K.W. Widyanarka, A.P. Bayuseno
The Virtual Machining process for the upper plate pattern master machining consists of 7 toolpath steps, namely: Roughing the entire surface using the Model Area Clearance strategy with an EndMill 6 mm cutting tool. This process took 12 hours 53 minutes 25 seconds.The process of finishing the flat surface outside the plate profile using the Optimized Constant Z Finishing toolpath strategy with the cutting tool still 6 mm Endmill. This process takes 1 hour 55 minutes 37 seconds.The process of finishing flat on the inside of the plate using the Spiral finishing strategy with a 6 mm EndMill cutting tool. The toolpath technique of walking in a circle along the flat surface of the center of the plate is very helpful for the evenness of the surface. This process took 21 minutes 42 seconds. The Spiral finishing strategy is especially suitable for flat surfaces with circular shapes.The finishing process for locking the mold uses the Optimized Constant Z Finishing strategy with Ballnosed Tool cutting 2 mm. The shape of the mold lock in the form of a circle with a curved contour of a radius requires that the finishing process be carried out with a cutting tool that has a tip that is also less than the radius of the contour to be worked on. Ideally slightly below the contour radius of the model, but here the largest available is Ballnosed 2 mm. This process took 2 hours 41 minutes 6 seconds.The semi-finishing process on the ornaments uses a Steep and Shallow Finishing strategy with a Ballnosed 2 mm cutting tool. This process bridges the previous roughing process using a 6 mm Endmill cutting tool to the finishing process using a small diameter cutting tool, namely Ballnosed 0.5 mm. This means that the Ballnosed cutting tool is 0.5 mm so that it does not work too hard for feeding. There is a decreasing contour, it is necessary to set it so that the step down is the same as the step over, the choice of this strategy is what distinguishes the Optimized Constant Z Finishing strategy. This process took 10 hours 56 minutes 25 seconds.The finishing process on the outer edge of the plate ornament uses the Steep and Shallow Finishing strategy with a Ballnosed 2 mm cutting tool. This process takes 3 hours 3 minutes 4 seconds.The finishing process for the ornament uses the Optimized Constant Z Finishing strategy with a Ballnosed cutting toll of 0.5 mm. This process took 91 hours 33 minutes 5 seconds.