The Experts below are selected from a list of 8535 Experts worldwide ranked by ideXlab platform
Stefan Simeonov Dimov - One of the best experts on this subject based on the ideXlab platform.
-
Material microstructure effects in micro-endmilling of Cu99.9E
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2016Co-Authors: Ahmed Elkaseer, Krastimir Borisov Popov, L. Olejnik, Stefan Simeonov Dimov, D T Pham, Andrzej RosochowskiAbstract:This article presents an investigation of the Machining Response of metallurgically and mechanically modified materials at the micro-scale. Tests were conducted that involved micro-milling slots in coarse-grained Cu99.9E with an average grain size of 30 µm and ultrafine-grained Cu99.9E with an average grain size of 200 nm, produced by equal channel angular pressing. A new method based on atomic force microscope measurements is proposed for assessing the effects of material homogeneity changes on the minimum chip thickness required for a robust micro-cutting process with a minimum surface roughness. The investigation has shown that by refining the material microstructure the minimum chip thickness can be reduced and a high surface finish can be obtained. Also, it was concluded that material homogeneity improvements lead to a reduction in surface roughness and surface defects in micro-cutting.
-
The effect of material grain structure on the surface integrity of components processed by microwire electrical discharge Machining (μWEDM)
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2011Co-Authors: Andrew Rees, Roussi Minev, Andrzej Rosochowski, Stefan Simeonov Dimov, G. Lalev, Lech OlejnikAbstract:The Machining Response of metallurgically and mechanically modified materials when processed by employing the microwire electrical discharge Machining (µWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5000 series aluminium alloys after µWEDM processing is studied. The Machining Response of an ‘as received’ aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process–material effects on the resulting microhardness, phase content changes, heat-affected zone, surface roughness, microcracks, recast layer, material removal rate, and element spectrum after both rough and finishing µWEDM cuts were investigated. This study shows that an ultrafine grained (UFG) Al5083 exhibits not only superior mechanical properties but also the Machining Response to µWEDM is favourable. A reduction of the recast layer after WEDM was observed when compared with ‘as received’ and ‘conventionally’ processed Al5083.
-
Material Microstructure Effect-based Investigation of Tool Wear in Micro-endmilling of Multi-phase Materials
Proceedings of the 7th International Conference on Multi-Material Micro Manufacture, 2010Co-Authors: Ahmed Elkaseer, Krastimir Borisov Popov, Stefan Simeonov Dimov, Roussi MinevAbstract:This paper presents an investigation of the microstructure effects of multi-phase materials on tool wear at microscale Machining. A new generic method is developed to estimate the tool wear when Machining multi-phase materials. The average values of cutting edge radius and tool flute profile were used to estimate the tool wear. A new experimental setup was proposed to determine these two parameters, and series of experiments on two materials with distinctive properties were conducted in order to assess the validity of the proposed method. Especially, the Machining Response of pearlite and ferrite were studied independently to capture differences in their cutting conditions, and thus to model the effects of each phase on the tool wear. Then, based on the experimental data two regression models were created to estimate the increase of the cutting edge radius for pearlite and ferrite steel independently. To demonstrate the applicability of the proposed generic method and at the same time to validate the models, they were used to estimate the tool wear of AISI1040 as an example of dual-phase steel. A good agreement between the estimated tool wear and the experimental results was obtained; the average error was 17.9%. This empirical study demonstrates the validity of the proposed generic method for estimating the tool wear when Machining multi-phase materials.
-
The effect of surface integrity of components processed by μWEDM
2009Co-Authors: Andrew Rees, Roussi Minev, Andrzej Rosochowski, Stefan Simeonov Dimov, G. Lalev, Lech OlejnikAbstract:The Machining Response of metallurgically and mechanically modified materials when they are processed by employing the micro wire EDM (μWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5083 series aluminium alloys after μWEDM processing is investigated. The Machining Response of an "as received" aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process-material effects on the resulting phase content changes and surface hardness after both rough and finishing μWEDM cuts were analyzed. This study shows that an ultra-fine grain Al5083 material maintained its advantageous structural characteristics and superior mechanical properties after μWEDM. The machined surfaces of UFG material displayed a 30% higher micro hardness, when compared with 'as received' and 'conventionally' processed Al5083 aluminium.
-
Micromiling of coarse-grained and ultrafine-grained Cu99.9E: Effects of material microstructure on Machining conditions and surface quality
2009Co-Authors: Duc Truong Pham, Krastimir Borisov Popov, Ahmed Elkaseer, Stefan Simeonov Dimov, Lech Olejnik, Andrzej RosochowskiAbstract:This paper investigates the Machining Response of metallurgically and mechanically modified materials, in particular, coarse-grained (CG) Cu99.9E, with an average grain size of 30 µm and ultrafine-grained (UFG) Cu99.9E, with an average grain size of 200 nm, produced by Equal- Channel Angular Pressing (ECAP). A novel high-precision method for assessing the homogeneity of the material microstructure is proposed based on Atomic Force Microscope (AFM) measurements of the coefficient of friction at the atomic scale, enabling the prediction of the minimum chip thickness of the individual grains inside the bulk. The investigation has shown that by refining the material microstructure, the minimum chip thickness has been reduced and a high surface finish can be achieved. Also, the homogeneity of the material microstructure and the resulting surface quality have been improved.
Andrzej Rosochowski - One of the best experts on this subject based on the ideXlab platform.
-
Material microstructure effects in micro-endmilling of Cu99.9E
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2016Co-Authors: Ahmed Elkaseer, Krastimir Borisov Popov, L. Olejnik, Stefan Simeonov Dimov, D T Pham, Andrzej RosochowskiAbstract:This article presents an investigation of the Machining Response of metallurgically and mechanically modified materials at the micro-scale. Tests were conducted that involved micro-milling slots in coarse-grained Cu99.9E with an average grain size of 30 µm and ultrafine-grained Cu99.9E with an average grain size of 200 nm, produced by equal channel angular pressing. A new method based on atomic force microscope measurements is proposed for assessing the effects of material homogeneity changes on the minimum chip thickness required for a robust micro-cutting process with a minimum surface roughness. The investigation has shown that by refining the material microstructure the minimum chip thickness can be reduced and a high surface finish can be obtained. Also, it was concluded that material homogeneity improvements lead to a reduction in surface roughness and surface defects in micro-cutting.
-
Effect of material microstructure on the micro-EDM process
2013Co-Authors: Ahmed Elkaseer, Anthony Surleraux, Samuel Bigot, Andrzej RosochowskiAbstract:This paper presents a preliminary experimental study of the factors affecting the micro-EDM process aiming at obtaining a deeper understanding of the micro-EDM die sinking process. In particular, the Machining Response at micro-scale of materials metallurgically and mechanically modified has been investigated. Tests were conducted that involved producing micro-EDM holes in course grained (CG) Al1070 with an average grain size of 300 m and Ultra Fine Grained (UFG) Al1070 with an average grain size of 0.6 m, produced by Equal-Channel Angular Pressing (ECAP). These experimental trials were carried out under different levels of applied energy, voltage, maximum current and pulse duration in order to identify the effects of these process conditions on the obtainable surface roughness, wear ratio, craters and spark gap. The results of this investigation have revealed that, by refining the material microstructure, a better surface finish can be achieved. This observation can be mainly attributed to the homogeneity of the refined material microstructure that normally leads to more isotropic behavior of the microstructure. Furthermore, the applied energy is found to be the most important factor affecting the roughness average and wear ratio in the micro-EDM process. However, the applied voltage is found to be the second effective factor on wear ratio, while the interaction of energy and current have a significant influence on the surface roughness.
-
Effect of material microstructure on the micro-EDM process ICOMM 2013
2013Co-Authors: Ahmed Elkaseer, Anthony Surleraux, Samuel Bigot, Andrzej RosochowskiAbstract:This paper presents a preliminary experimental study of the factors affecting the micro-EDM process aiming at obtaining a deeper understanding of the micro-EDM die sinking process. In particular, the Machining Response at micro-scale of materials metallurgically and mechanically modified has been investigated. Tests were conducted that involved producing micro-EDM holes in course grained (CG) Al1070 with an average grain size of 300 �m and Ultra Fine Grained (UFG) Al1070 with an average grain size of 0.6 �m, produced by Equal-Channel Angular Pressing (ECAP). These experimental trials were carried out under different levels of applied energy, voltage, maximum current and pulse duration in order to identify the effects of these process conditions on the obtainable surface roughness, wear ratio, craters and spark gap. The results of this investigation have revealed that, by refining the material microstructure, a better surface finish can be achieved. This observation can be mainly attributed to the homogeneity of the refined material microstructure that normally leads to more isotropic behavior of the microstructure. Furthermore, the applied energy is found to be the most important factor affecting the roughness average and wear ratio in the micro-EDM process. However, the applied voltage is found to be the second effective factor on wear ratio, while the interaction of energy and current have a significant influence on the surface roughness.
-
The effect of material grain structure on the surface integrity of components processed by microwire electrical discharge Machining (μWEDM)
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2011Co-Authors: Andrew Rees, Roussi Minev, Andrzej Rosochowski, Stefan Simeonov Dimov, G. Lalev, Lech OlejnikAbstract:The Machining Response of metallurgically and mechanically modified materials when processed by employing the microwire electrical discharge Machining (µWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5000 series aluminium alloys after µWEDM processing is studied. The Machining Response of an ‘as received’ aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process–material effects on the resulting microhardness, phase content changes, heat-affected zone, surface roughness, microcracks, recast layer, material removal rate, and element spectrum after both rough and finishing µWEDM cuts were investigated. This study shows that an ultrafine grained (UFG) Al5083 exhibits not only superior mechanical properties but also the Machining Response to µWEDM is favourable. A reduction of the recast layer after WEDM was observed when compared with ‘as received’ and ‘conventionally’ processed Al5083.
-
The effect of surface integrity of components processed by μWEDM
2009Co-Authors: Andrew Rees, Roussi Minev, Andrzej Rosochowski, Stefan Simeonov Dimov, G. Lalev, Lech OlejnikAbstract:The Machining Response of metallurgically and mechanically modified materials when they are processed by employing the micro wire EDM (μWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5083 series aluminium alloys after μWEDM processing is investigated. The Machining Response of an "as received" aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process-material effects on the resulting phase content changes and surface hardness after both rough and finishing μWEDM cuts were analyzed. This study shows that an ultra-fine grain Al5083 material maintained its advantageous structural characteristics and superior mechanical properties after μWEDM. The machined surfaces of UFG material displayed a 30% higher micro hardness, when compared with 'as received' and 'conventionally' processed Al5083 aluminium.
Ahmed Elkaseer - One of the best experts on this subject based on the ideXlab platform.
-
Material microstructure effects in micro-endmilling of Cu99.9E
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2016Co-Authors: Ahmed Elkaseer, Krastimir Borisov Popov, L. Olejnik, Stefan Simeonov Dimov, D T Pham, Andrzej RosochowskiAbstract:This article presents an investigation of the Machining Response of metallurgically and mechanically modified materials at the micro-scale. Tests were conducted that involved micro-milling slots in coarse-grained Cu99.9E with an average grain size of 30 µm and ultrafine-grained Cu99.9E with an average grain size of 200 nm, produced by equal channel angular pressing. A new method based on atomic force microscope measurements is proposed for assessing the effects of material homogeneity changes on the minimum chip thickness required for a robust micro-cutting process with a minimum surface roughness. The investigation has shown that by refining the material microstructure the minimum chip thickness can be reduced and a high surface finish can be obtained. Also, it was concluded that material homogeneity improvements lead to a reduction in surface roughness and surface defects in micro-cutting.
-
Effect of material microstructure on the micro-EDM process
2013Co-Authors: Ahmed Elkaseer, Anthony Surleraux, Samuel Bigot, Andrzej RosochowskiAbstract:This paper presents a preliminary experimental study of the factors affecting the micro-EDM process aiming at obtaining a deeper understanding of the micro-EDM die sinking process. In particular, the Machining Response at micro-scale of materials metallurgically and mechanically modified has been investigated. Tests were conducted that involved producing micro-EDM holes in course grained (CG) Al1070 with an average grain size of 300 m and Ultra Fine Grained (UFG) Al1070 with an average grain size of 0.6 m, produced by Equal-Channel Angular Pressing (ECAP). These experimental trials were carried out under different levels of applied energy, voltage, maximum current and pulse duration in order to identify the effects of these process conditions on the obtainable surface roughness, wear ratio, craters and spark gap. The results of this investigation have revealed that, by refining the material microstructure, a better surface finish can be achieved. This observation can be mainly attributed to the homogeneity of the refined material microstructure that normally leads to more isotropic behavior of the microstructure. Furthermore, the applied energy is found to be the most important factor affecting the roughness average and wear ratio in the micro-EDM process. However, the applied voltage is found to be the second effective factor on wear ratio, while the interaction of energy and current have a significant influence on the surface roughness.
-
Effect of material microstructure on the micro-EDM process ICOMM 2013
2013Co-Authors: Ahmed Elkaseer, Anthony Surleraux, Samuel Bigot, Andrzej RosochowskiAbstract:This paper presents a preliminary experimental study of the factors affecting the micro-EDM process aiming at obtaining a deeper understanding of the micro-EDM die sinking process. In particular, the Machining Response at micro-scale of materials metallurgically and mechanically modified has been investigated. Tests were conducted that involved producing micro-EDM holes in course grained (CG) Al1070 with an average grain size of 300 �m and Ultra Fine Grained (UFG) Al1070 with an average grain size of 0.6 �m, produced by Equal-Channel Angular Pressing (ECAP). These experimental trials were carried out under different levels of applied energy, voltage, maximum current and pulse duration in order to identify the effects of these process conditions on the obtainable surface roughness, wear ratio, craters and spark gap. The results of this investigation have revealed that, by refining the material microstructure, a better surface finish can be achieved. This observation can be mainly attributed to the homogeneity of the refined material microstructure that normally leads to more isotropic behavior of the microstructure. Furthermore, the applied energy is found to be the most important factor affecting the roughness average and wear ratio in the micro-EDM process. However, the applied voltage is found to be the second effective factor on wear ratio, while the interaction of energy and current have a significant influence on the surface roughness.
-
AFM probe-based mechanical Machining: Modelling of the surface generation process
2012Co-Authors: Ahmed Elkaseer, Emmanuel Bruno Jean Paul BrousseauAbstract:his paper presents a study on the modelling and investiga-tion of the surface generation process during Atomic Force Microscopy (AFM) probe-based mechanical Machining of dual-phase materials. The proposed model considers the ef-fects of the cutting tip geometry, the step-over between linear machined grooves and the minimum chip thickness as well as the elastic recovery of different phases present within the workpiece microstructure. In particular, the model takes into account changes in the Machining Response between phases, i.e. transitions from cutting to ploughing and vice versa, and the influence of such variations on the machined surface. These alterations in the Machining Response are mainly at-tributed to the dissimilarity in the values of the minimum chip thickness and the elastic recovery of the different processed phases. Therefore, investigations were initially conducted to examine the phases to be machined and thus to identify some of their mechanical properties.
-
Modelling, simulation and experimental investigation of the effects of material microstructure on the micro-endmiling process
2011Co-Authors: Ahmed ElkaseerAbstract:Recently it has been revealed that workpiece microstructure has dominant effects on the performance of the micro-Machining process. However, so far, there has been no detailed study of these effects on micro-endmilling. In this research, the influence of the microstructure on the matters such as cutting regime, tool wear and surface quality has been investigated. Initially, an experimental investigation has been carried out to identify the Machining Response of materials metallurgically and mechanically modified at the micro-scale. Tests have been conducted that involved micro-milling slots in coarse-grained (CG) Cu99.9E with an average grain size of 30 μm and ultrafine-grained (UFG) Cu99.9E with an average grain size of 200 nm. Then, a method of assessing the homogeneity of the material microstructure has been proposed based on Atomic Force Microscope (AFM) measurements of the coefficient of friction at the atomic scale, enabling a comparative evaluation of the modified microstructures. The investigation has shown that, by refining the material microstructure, the minimum chip thickness can be reduced and a better surface finish can be achieved. Also, the homogeneity of the microstructure can be improved which in turn reduces surface defects. Furthermore, a new model to simulate the surface generation process during micro- endmilling of dual-phase materials has been developed. The proposed model considers the effects of the following factors: the geometry of the cutting tool, the feed rate, and the workpiece microstructure. In particular, variations of the minimum chip thickness at phase boundaries are considered by feeding maps of the microstructure into the model. Thus, the model takes into account these variations that alter the Machining mechanism from a proper cutting to ploughing and vice versa, and are the main cause of micro-burr formation. By applying the proposed model it is possible to estimate more accurately the resulting roughness owing to the dominance of the micro-burrs formation during the surface generation process in micro-milling of multi-phase materials. The model has been experimentally validated by Machining two different samples of dual-phase steel, AISI 1040 and AISI 8620, under a range of chip-loads. The results have shown that the proposed model accurately predicts the roughness of the machined surfaces with average errors of 14.5% and 17.4% for the AISI 1040 and AISI 8620 samples, respectively. The developed model successfully elucidates the mechanism of micro-burr formation at the phase boundaries, and quantitatively describes its contributions to the resulting surface roughness after micro-endmilling. (Abstract shortened by UMI.).
Ko-ta Chiang - One of the best experts on this subject based on the ideXlab platform.
-
The method of grey-fuzzy logic for optimizing multi-Response problems during the manufacturing process: a case study of the light guide plate printing process
The International Journal of Advanced Manufacturing Technology, 2008Co-Authors: Nun-ming Liu, Jenn-tsong Horng, Ko-ta ChiangAbstract:In this paper, a method of grey-fuzzy logic based on the orthogonal array is proposed to achieve the optimization of multi-Response characteristics during the manufacturing process. The optimal procedure proposed for solving the optimal multi-Response problem applies the grey relational coefficient in each Machining Response and converts a grey-fuzzy reasoning grade so as to evaluate multiple-Machining Responses. One real case study performed in the light guide plate (LGP) printing process verifies that the optimum procedure proposed in this study is feasible and effective. Through the grey-fuzzy logic analysis, the printing processing parameters, namely mixed rate of ink, velocity and pressure of printing process, and material and angle of scraper, are optimized with considerations to the multiple Machining Responses, including illumination, homogeny, value of variance for the illumination and printing ink thickness. The experimental results using the optimal setting easily clarified that the above-mentioned optimum procedure greatly improved the manufacturing process in this study.
-
the optimal process conditions of an injection molded thermoplastic part with a thin shell feature using grey fuzzy logic a case study on Machining the pc abs cell phone shell
Materials & Design, 2007Co-Authors: Ko-ta ChiangAbstract:This paper presents a fast and effective methodology for the optimal process conditions of an injection-molded thermoplastic part with a thin shell feature based on the orthogonal array with the grey relational analysis and fuzzy logic. The proposed optimal procedure in solving the optimal multi-Responses problem applies the grey relational coefficient for each Machining Response and converts a grey-fuzzy reasoning grade to evaluate the multiple Machining Responses. One real case study in the injection molding process of Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS) cell phone shell has been performed to substantiate the proposed optimal procedure in order to indicate its feasibility and effectiveness. Through the grey-fuzzy logic analysis, the principle injection molding parameters, namely the opening mold cavity time, mold temperature, melt temperature, filling time, filling pressure, packing time, packing pressure and cooling time, are optimized with considerations of multiple Machining Responses including the strength of welding line, shrinkage and difference of forming distributive temperature. The results of confirmation test with the optimal levels of process parameters have obviously shown that the above Machining Responses in the injection molding process can be improved effectively together through this procedure. In addition, the analysis of variance (ANOVA) is utilized to find the effect of Machining parameters on the multiple Machining Responses problem of the injection molding process.
Roussi Minev - One of the best experts on this subject based on the ideXlab platform.
-
The effect of material grain structure on the surface integrity of components processed by microwire electrical discharge Machining (μWEDM)
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2011Co-Authors: Andrew Rees, Roussi Minev, Andrzej Rosochowski, Stefan Simeonov Dimov, G. Lalev, Lech OlejnikAbstract:The Machining Response of metallurgically and mechanically modified materials when processed by employing the microwire electrical discharge Machining (µWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5000 series aluminium alloys after µWEDM processing is studied. The Machining Response of an ‘as received’ aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process–material effects on the resulting microhardness, phase content changes, heat-affected zone, surface roughness, microcracks, recast layer, material removal rate, and element spectrum after both rough and finishing µWEDM cuts were investigated. This study shows that an ultrafine grained (UFG) Al5083 exhibits not only superior mechanical properties but also the Machining Response to µWEDM is favourable. A reduction of the recast layer after WEDM was observed when compared with ‘as received’ and ‘conventionally’ processed Al5083.
-
Material Microstructure Effect-based Investigation of Tool Wear in Micro-endmilling of Multi-phase Materials
Proceedings of the 7th International Conference on Multi-Material Micro Manufacture, 2010Co-Authors: Ahmed Elkaseer, Krastimir Borisov Popov, Stefan Simeonov Dimov, Roussi MinevAbstract:This paper presents an investigation of the microstructure effects of multi-phase materials on tool wear at microscale Machining. A new generic method is developed to estimate the tool wear when Machining multi-phase materials. The average values of cutting edge radius and tool flute profile were used to estimate the tool wear. A new experimental setup was proposed to determine these two parameters, and series of experiments on two materials with distinctive properties were conducted in order to assess the validity of the proposed method. Especially, the Machining Response of pearlite and ferrite were studied independently to capture differences in their cutting conditions, and thus to model the effects of each phase on the tool wear. Then, based on the experimental data two regression models were created to estimate the increase of the cutting edge radius for pearlite and ferrite steel independently. To demonstrate the applicability of the proposed generic method and at the same time to validate the models, they were used to estimate the tool wear of AISI1040 as an example of dual-phase steel. A good agreement between the estimated tool wear and the experimental results was obtained; the average error was 17.9%. This empirical study demonstrates the validity of the proposed generic method for estimating the tool wear when Machining multi-phase materials.
-
The effect of surface integrity of components processed by μWEDM
2009Co-Authors: Andrew Rees, Roussi Minev, Andrzej Rosochowski, Stefan Simeonov Dimov, G. Lalev, Lech OlejnikAbstract:The Machining Response of metallurgically and mechanically modified materials when they are processed by employing the micro wire EDM (μWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5083 series aluminium alloys after μWEDM processing is investigated. The Machining Response of an "as received" aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process-material effects on the resulting phase content changes and surface hardness after both rough and finishing μWEDM cuts were analyzed. This study shows that an ultra-fine grain Al5083 material maintained its advantageous structural characteristics and superior mechanical properties after μWEDM. The machined surfaces of UFG material displayed a 30% higher micro hardness, when compared with 'as received' and 'conventionally' processed Al5083 aluminium.
-
micromilling material microstructure effects
Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2006Co-Authors: Krastimir Borisov Popov, Roussi Minev, Andrzej Rosochowski, Stefan Simeonov Dimov, D T Pham, L. OlejnikAbstract:Micromilling is one of the technologies that is currently widely used for the production of microcomponents and tooling inserts. To improve the quality and surface finish of machined microstructures the factors affecting the process dynamic stability should be studied systematically. This paper investigates the Machining Response of a metallurgically and mechanically modified material. The results of micromilling workpieces of an Al 5000 series alloy with different grain microstructures are reported. In particular, the Machining Response of three Al 5083 workpieces whose microstructure was modified through a severe plastic deformation was studied when milling thin features in microcomponents. The effects of the material microstructure on the resulting part quality and surface integrity are discussed and conclusions made about its importance in micromilling. The investigation has shown that through a refinement of material microstructure it is possible to improve significantly the surface integrity of the microcomponents and tooling cavities produced by micromilling.
-
The effects of material microstructure in micro-milling
4M 2006 - Second International Conference on Multi-Material Micro Manufacture, 2006Co-Authors: Krastimir Borisov Popov, Roussi Minev, Andrzej Rosochowski, L. Olejnik, Stefan Simeonov Dimov, D T Pham, Maria RichertAbstract:Abstract Micro-milling is one of the technologies that is currently widely used for the production of micro-components and tooling inserts. To improve the quality and surface finish of machined microstructures the factors affecting the process dynamic stability should be studied systematically. This paper investigates the Machining Response of a metallurgically and mechanically modified material. The results of micro-milling workpieces of an Al 5000 series alloy with different grain microstructure are reported. In particular, the Machining Response of three Al 5083 workpieces whose microstructure was modified through a severe plastic deformation was studied when milling thin features in microcomponents. The effects of the material microstructure on the resulting part quality and surface integrity are discussed and conclusions made about its importance in micro-milling. The investigation has shown that through a refinement of material microstructure it is possible to improve significantly the surface integrity of the micro-components and tooling cavities produced by micro-milling.
