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Ball end micro milling of areal material measures: influence of the tilt angle on the resulting surface topography

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Abstract

Topography measuring instruments are calibrated by using material measures to estimate the measurement uncertainty and to ensure traceability. In ISO 25178-70, areal material measures are standardized, but no manufacturing process for their generation is defined. Therefore, previous studies examined the capabilities of multiple manufacturing principles for this application. Micro milling is an adequate process when the manufacturing of freeform surfaces in metal is required; it was proven that micro milling also is a generally suitable process for the manufacturing of material measures. In previous investigations, a study analyzing the influence of the control dataset design on the resulting surface quality of the micro milled material measures was carried out. It was shown that some control data parameters have a crucial influence on the surface quality, e.g. the tilt angle. When using ball end micro mills, a tilt angle prevents a cutting speed equal to zero in the mill’s center. When too small tilt angles are applied, ploughing of the material instead of a cutting occurs. However, at high tilt angles other effects that can lead to deviations between the target geometry dataset and machined geometry occur. In this experimental study the tilt angle’s influence on the resulting roughness and machined geometry was examined by micro milling sinusoidal freeform surfaces at different tilt angles. In addition to the deviation between intended and machined geometry and the roughness of the manufactured surfaces the correlations of the mentioned parameters to the tilt angle were additionally evaluated.

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Notes

  1. Naming of specific manufacturers is done solely for the sake of completeness and does not necessarily imply an endorsement of the named companies nor that the products are necessarily the best for the purpose.

Abbreviations

A :

Tilt angle

ACS :

Areal Crossed Sinusoidal material measure (ISO 25178-70)

AFL :

Areal Plane Surface material measure (ISO 25178-70)

d :

Amplitude for chosen geometries (ACS, PPS according to ISO 25178-70)

D :

Tool path discretization

deviationper():

Percentage deviation from target value

f t :

Feed per tooth

L :

Distance between two tool paths

L c :

Filter cutoff wavelength

n :

Rotational speed

p :

Period length for chosen geometries (ACS, PPS according to ISO 25178-70)

PPS :

Profile Periodic Sinus Structure material measure (ISO 25178-70)

Sa :

Arithmetic mean height

Sa05-25 :

Arithmetic mean height after filtering with λc = 25 μm and λs = 5 μm

Sa80 :

Arithmetic mean height after filtering with λc = 80 μm

Sq :

Root mean square height

Sq80 :

Root mean square height after filtering with λc = 80 μm

Sq05-25 :

Root mean square height after filtering with λc = 25 μm and λs = 5 μm

T :

Tool (diamond) r = 100 µm, single-edged

r :

Tool radius (effective cutter radius)

v f :

Feed rate

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Acknowledgements

Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)—Projektnummer 172116086-SFB 926.

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Authors and Affiliations

  1. Institute for Manufacturing Technology and Production Systems, TU Kaiserslautern, Gottlieb-Daimler Str., 67663, Kaiserslautern, Germany

    K. Klauer, B. Kirsch & J. C. Aurich

  2. Institute for Measurement and Sensor-Technology, TU Kaiserslautern, Gottlieb-Daimler Str., 67663, Kaiserslautern, Germany

    M. Eifler & J. Seewig

Authors
  1. K. Klauer
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  2. M. Eifler
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  3. B. Kirsch
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  4. J. Seewig
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  5. J. C. Aurich
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Correspondence to K. Klauer.

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Appendix

Appendix

See Fig. 10.

Fig. 10
figure 10

Topographies, confocal microscope images for tilt angle study with constant amplitude

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Klauer, K., Eifler, M., Kirsch, B. et al. Ball end micro milling of areal material measures: influence of the tilt angle on the resulting surface topography. Prod. Eng. Res. Devel. 14, 239–252 (2020). https://doi.org/10.1007/s11740-019-00943-x

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