ABSTRACT

Micro endmilling is emerged as a potential micromachining technique in many industries like biomedical, aerospace, optics, electronics and marine, etc. due to the huge demand for micro components with precision. However, relatively higher tool wear and poor surface characteristics are limiting its applicability in many areas. Therefore, the need has been raised to improve the machining characteristics of micro endmilling sustainably. The size effect and micro endmilling performance such as wear behavior, cutting force, and microhardness under dry and sunflower oil based MQL environments while machining on Inconel 718 was studied in this work. Results showed that the sunflower oil based MQL environments have the potential to reduce the size effect region and tool wear significantly. Workpiece adhesion and abrasion on the cutting edge were identified as the main underlying wear mechanism for both conditions. The edge radius, tool flank wear, and cutting forces were found to be reduced by 25%, 30%, and 36% respectively with the application of MQL compared to dry conditions. In addition, an increase of 7% in microhardness with relatively smooth surfaces as well as reduced micro cracks, prows, and voids on the machined surfaces were observed with the application of MQL.

摘要

由于对精密微型零件的巨大需求，微型端铣削已成为许多行业的潜在微加工技术，例如生物医学，航空航天，光学，电子和航海等。但是，相对较高的工具磨损和较差的表面特性限制了其在许多领域的适用性。因此，提出了持续改善微端面铣削的加工特性的需求。在这项工作中，研究了在基于Inconel 718进行加工的基于干油和葵花籽油的MQL环境下的尺寸效应和微型立铣刀性能，例如磨损行为，切削力和显微硬度。结果表明，基于葵花籽油的MQL环境有可能显着减小尺寸影响区域和工具磨损。两种情况下，工件在切削刃上的粘附和磨损被认为是主要的潜在磨损机理。与干燥条件相比，使用MQL可以分别将刀刃半径，刀具侧面磨损和切削力分别降低25％，30％和36％。此外，使用MQL可以观察到，相对光滑的表面使显微硬度提高了7％，并且减少了加工表面上的微裂纹，尖角和空隙。