Micro-grinding of Micro-groove Array on Tool Rake Surface for Dry Cutting of Titanium Alloy

Jin Xie,Min-Jian Luo,Jian-Lin He,Xu-Ran Liu,Ting-Wu Tan 한국정밀공학회 2012 International Journal of Precision Engineering and Vol. No.

A micro-grinding approach is proposed to fabricate micro-groove array on tool rake surface. These micro-grooves were used to rapidly dissipate cutting chips and heat from cutting zone for eco-cutting of titanium alloy without any coolant. This tool is called micro-grooved tool. The objective is to replace chemical and high-energy-beam etching approaches because they have not yet been able to control micron-scale groove shape accuracy. In this study, a superhard diamond wheel V-tip was employed to perform a micro-grinding through a traverse grinding. After micro-grinding, these micro-grooves were characterized by the mean depth of 155.1 μm, the mean form error PV of 7.8 μm and the mean tip radius of 45.6 μm. Firstly, traditional plate tool, orthogonal micro-grooved tool and diagonal micro-grooved tool were employed to perform a dry turning of titanium alloy, respectively; then, tool wear, surface roughness, chip topography and shear angle were investigated. It is shown that the sharpened diamond wheel V-tip is valid to grinding micro-groove array on tool rake surface without any burrs. Furthermore, the micro-grooved tools may reduce the cutting sparks, tool wear, 3D chip size and chip saw-tooth size compared to traditional plate tool. The diagonal micro-grooved tool may decrease tool wear by 6.7% and surface roughness by 37.3% and increase shear angle by 24.3% against orthogonal micro-grooved tool, respectively. This is because the diagonal micro-grooving direction is identical to the cutting chip flowing on tool rake surface. It is confirmed that the diagonal micro-grooved tool is applicable to a stable dry cutting of titanium alloy.

Shape Optimization of Grooved Micro-Channel Heat Sink

Danish Ansari(대니쉬),Afzal Husain(아프잘),Kwang-Yong Kim(김광용) 대한기계학회 2009 대한기계학회 춘추학술대회 Vol.2009 No.11

Micro-channel heat sink with groove structure has been optimized by using multi-objective evolutionary algorithm. The thermal resistance and pumping power characteristics of the micro-channel heat sink have been investigated numerically. For optimization, four design variables, i.e., the ratios of the groove depth to the micro-channel height, the groove pitch to the micro-channel height, the groove diameter to pitch, and the micro-channel width to height, are selected. The thermal resistance and the pumping power are the objective functions. The Navier-Stokes and energy equations for laminar flow and conjugate heat transfer are solved using a finite-volume solver. Grooved micro-channel shows decrease in thermal resistance and increase in Nusselt number over smooth micro-channel. The thermal resistance in a grooved micro-channel is lower than that in a smooth micro-channel for a fixed pumping power.

Research on optimization of milling performance of V-groove micro-texture ball-end milling cutter

Shucai Yang,Chaoyang Guo,Wei Ren 대한기계학회 2022 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.36 No.6

Titanium alloys generally have problems such as sticking, large cutting force, and poor heat dissipation during the cutting process., research shows that processing microtextures on the surface of the tool can effectively improve the above problems. Therefore, this paper designs the V-groove micro-textures based on the principle of bionics. Use simulation software to analyze the milling behavior of different V-groove micro-texture ball-end milling cutters for milling titanium alloys. Build a test platform to study the milling performance of the Vgroove micro-texture ball-end milling cutter for milling titanium alloys, obtain the prior choice range of V-groove micro-texture parameters, optimize the parameters based on the simulated annealing algorithm and conduct experimental verification. The results of the optimal tool parameters are that the opening angle of the V-groove micro-textures is 79°, the V-groove microtexture spacing is 170 μm, and the V-groove micro-texture width is 30 μm, the distance from blade of the V-groove micro-textures is 90 μm.

Novel Environmentally Friendly Manufacturing Method for Micro-Textured Cutting Tools

Changping Li,Xinyi Qiu,Zhen Yu,Shujian Li,Pengnan Li,Qiulin Niu,Rendi Kurniawan,고태조 한국정밀공학회 2021 International Journal of Precision Engineering and Vol.8 No.1

Surface texturing on cutting tools has a great influence on reducing the friction force between tool and chip interfaces. In this study, a grinding method was developed to fabricate micro-groove textures on cutting tools using a special diamond grinding wheel on the tool rake face. A comparative experiment was done using a laser and other grinding method to fabricate micro-grooves. The developed grinding method does not produce harmful gases, it is environmentally friendly, and it fabricates groove textures with high efficiency and quality. Various micro-grooves with depths of 30–90 μm, groove pitches of 0.5–1 mm, and groove angles of 30–60 o were made on the rake faces of non-coated end-mill tools using the developed grinding method. Milling experiments on aluminum alloy (Al6061-T6) and tool steel (SKD11) with non-water-soluble coolant were carried out using the textured tools, and the cutting force and tool wear were investigated. In most cases, the cutting force produced by the micro-grooved tools is significantly reduced. In addition, the wear resistance of the micro-groove cutting tool is better than that of a conventional cutting tool, and there is no chipping.

C-means 알고리즘을 이용한 마이크로 엔드밀의 상태 감시

권동희,정연식,강익수,김전하,김정석 한국공작기계학회 2005 한국공작기계학회 춘계학술대회논문집 Vol.2005 No.-

Recently, the advanced industries using micro parts are rapidly growing. Micro end milling is one of the prominent technology that has wide spectrum of application field ranging from macro to micro parts. Also, the method of micro-grooving using micro end milling is used widely owing to many merit, but has problems of precision and quality of products due to tool wear and tool fracture. This study deals with condition monitoring using acoustic emission(AE) signal in the micro-grooving. First, the feature extraction of AE signal directly related to machining process is executed. Then, the distinctive micro end mill state according to the each tool condition is classified by using the fuzzy C-means algorithm, which is one of the methods to recognize data patterns. These result is effective monitoring method of micro end mill state by the AE sensing techniques which can be expected to be applicable to micro machining processes in the future.

Numerical investigation of the effects of geometric parameters on transverse motion with slanted-groove micro-mixers

Seung Joo Baik,Jae Yong Cho,최세빈,이준상 대한기계학회 2016 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.30 No.8

We investigated hydrodynamic phenomena inside several passive microfluidic mixers using a Lattice Boltzmann method (LBM) based on particle mesoscopic kinetic equations. Mixing processes were simulated in a Slanted grooved micro-mixer (SGM), a Staggered herringbone grooved micro-mixer (SHM), and a Bi-layered staggered herringbone grooved micro-mixer (BSHM). Then, the effects of six geometric mixer parameters (i.e., groove height to channel height ratio, groove width to groove pitch length ratio, groove pitch to groove height ratio, groove intersection angle, herringbone groove asymmetric ratio and bi-layered groove asymmetric ratio) on mixing were investigated using computed cross-flow velocity and helicity density distributions in the flow cross-section. We demonstrated that helicity density provides sufficient information to analyze micro helical motion within a micro-mixer, allowing for micro-mixer design optimization.

Improvement of Form Accuracy of Micro-Features on Thin, Large-area Plate using Fast Depth Adjustment in Micro-grooving

Dong Bae Kang(강동배),Seong Min Son(손성민),Hyo Ryeol Lee(이효렬),Jung Hwan Ahn(안중환) 한국생산제조학회 2013 한국생산제조학회지 Vol.22 No.3

Micro-features such as grooves and lenses, which perform optical functions in flat displays, should be manufactured with a good form accuracy because this is directly related to their optical performance. As the size of the display increases, it is very difficult to maintain a high relative accuracy because of the inherent geometric errors such as the waviness of a large-area plate. In this paper, the optical effect of these geometric errors is investigated, and surface-referenced micro-grooving to measure and compensate for such geometric errors on line is proposed to improve the form accuracy of the micro-grooves. A PZT-based fast depth adjustment servo system is implemented in the tool holder to maintain a uniform groove depth in reference to the wavy surface. Through experiments, the proposed method is shown to be an efficient way to produce high-quality micro- grooves on a wavy die surface.

황동의 Micro Groove 가공시 절삭칩과 표면거칠기

민경탁(Kyung Tak Min),장호수(Ho Su Jang) 한국기계가공학회 2010 한국기계가공학회지 Vol.9 No.4

Recently optical and electric and electronic forms in the field of ultra fine patterns has been used extensively, and techniques of the optical parts are required that can precision-machine this micro-patterns such as V or Rshaped micro-groove patterns. In this study, V and R type, shaping the way micro groove brass machining process to characterize the material feed rate and cutting depth and the V and R as a variable brother, using two kinds of diamond tools for each picture shape and surface roughness caused by conditions such as chips, processed through the analysis of effects of geometry and analysis such as precision machining.

다이어몬드 공구를 이용한 Ni 도금층의 정밀미세가공 시 절삭성

김선아(Seon Ah Kim),박동삼(Dong Sam Park) 한국생산제조학회 2009 한국생산제조학회지 Vol.18 No.6

Recently, expansion of micro-technology parts requires micro-precision machining technology. Micro-groove machining is important to fabricate micro-grating lens and many micro-parts such as microscope lens, fluidic graphite channel etc. Conventional groove fabrication methods such as etching and lithography have some problems in efficiency and surface integrity. But, mechanical micromachining methods using single crystal diamond tools can reduce these problems in chemical process. For this reason, microfabrication methods are expected to be very efficient, and widely studied. This study deals with machinability in micro-precision V-grooves machining of nickel plated layer using non-rotational single crystal diamond tool and 3-axis micro stages. Micro V-groove shape, chip formation and tool wear were investigated for the analysis of machinability of Ni plated layer.

A Study on Critical Depth of Cuts in Micro Grooving

Son, Seong-Min,Lim, Han-Seok,Paik, In-Hwan,Ahn, Jung-Hwan The Korean Society of Mechanical Engineers 2003 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.17 No.2

Ultra precision diamond cutting is a very efficient manufacturing method for optical parts such as HOE, Fresnel lenses, diffraction lenses, and others. During micro cutting, the rake angle is likely to become negative because the tool edge radius is considerably large compared to the sub-micrometer-order depth of cut. Depending on the ratio of the tool edge radius to the depth of cut, different micro-cutting mechanism modes appear. Therefore, the tool edge sharpness is the most important factor which affects the qualities of machined parts. That is why diamond, especially monocrystal diamond which has the sharpest edge among all other materials, is widely used in micro-cutting. The majar issue is regarding the minimum (critical) depth of cut needed to obtain continuous chips during the cutting process. In this paper, the micro machinability near the critical depth of cut is investigated in micro grooving with a diamond tool. The experimental results show the characteristics of micro-cutting in terms of cutting force ratio (Fx/Fy), chip shape, surface roughness, and surface hardening nea. the critical depth of cut.