Suppressing the burr of high aspect ratio structure by optimizing the cutting parameters in the micro-milling process
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ORIGINAL ARTICLE
Suppressing the burr of high aspect ratio structure by optimizing the cutting parameters in the micro-milling process Ni Chen 1 & Xinlei Zhang 1 & Jinming Wu 2 & Yang Wu 1 & Liang Li 1 & Ning He 1 Received: 29 June 2020 / Accepted: 14 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract High aspect ratio (HAR) structures are widely utilized in diverse applications, including the defense industries, medical treatment, and aerospace. Studies show that the micro-milling has superiorities such as high efficiency and high flexibility over other methods. Currently, the biggest problem of micro-milling is the influence of burrs on the milling performance, which is an enormous challenge to remove. In the present study, numerical simulations through the finite element method (FEM) and experiments are carried out to optimize cutting parameters of the specimen made of Cr12MoV alloy. Moreover, an improved constitutive model is proposed by considering the size effect of the micromilling. The proposed model is based on the J-C constitutive model, and it is concluded that the cutting force error is 4.6% through the comparison of experiment and FEM, which further proves the convergence of the improved constitutive model. It is also found that the side burr of HAR slots and the top burr of shallow slots are the biggest factors affecting the surface quality. The depth of cut (DoC) affects the maximum bending angle of the tool, the feed per tooth (FpT) affects the size of the unremoved area, and the spindle speed (SpS) affects the dynamic balance of the micro-mill, through the exploration of the above cutting parameters which can effectively improve the cutting state of the tool and finally achieve the purpose of curbing burr. Keywords Micro-milling . High aspect ratio (HAR) microstructures . Cutting parameters . Finite element method
1 Introduction Cr12MoV alloy is a cold work die steel with superior characteristics, including high hardenability, remarkable quenching and tempering hardness, wear resistance, and high strength when it is compared with the Cr12 alloy. Moreover, the Cr12MoV alloy can be used to manufacture thin-walled parts and parts that operate in severe working conditions. Accordingly, it is widely applied in the mold and aerospace industries [1, 2]. However, high Ni Chen and Xinlei Zhang contributed equally to this work and should be considered co-first authors. * Ni Chen [email protected] 1
Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics & Astronautics, Yudao Str. 29, Nanjing 210016, China
2
School of Mechanical Engineering, Southeast University, Nanjing 211189, People’s Republic of China
hardness of the Cr12MoV alloy makes it brittle so that nodular chips are simply produced during the machining process. Therefore, the machined surface of the specimen made of the Cr12MoV alloy has pit-like burrs. For high aspect ratio (HAR) slots studied in this paper, the side wall obstructs the discharge of chips, r
