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Experimental study of micromilling operation of stainless steel

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Abstract

The progress of technologies associated with manufacturing has made it possible to obtain miniaturized components, which are showing increased use in many areas. The micromilling process stands out in obtaining these components for manufacturing surfaces with high dimensional precision and desirable finish, besides making the manufacture of microcomponents with complex geometry in various materials possible. Considering the importance of micromilling in obtaining the miniaturized components, it is fundamental to carry out investigations on this cutting process. To contribute to these investigations, this work aims to study the influence of the cutting length of the microtools in the micromilling of AISI 316L stainless steel. The influence of the cutting length was evaluated from the wear of the microtools, the formation of burrs, and the surface roughness. Also, Euler Bernoulli beam model was used to calculate the deflection of the microtools. Two cutting lengths were used, 0.8 mm and 0.6 mm. Through this deflection analysis, it was possible to observe that the shrank part consists of the most rigid part of the microtools independent of the cutting length, while the conical part of the shortest microtool and the cutting part of the longest microtool were the ones that most contributed to the lower stiffness of each tool. According to the experimental results, the wear of the microtools as a function of the machined length is similar to the wear of conventional tools; therefore, it was possible to obtain the Taylor equation under the analyzed cutting condition. Regarding the analysis of the influence of the cut length of the microtools, it was observed that the microtools with shorter cut length have greater rigidity, therefore less deflection, and longer life. However, for the shorter microtool to have a longer life, the cutting conditions used, rotation, and depth of cut must be stable conditions, to avoid the appearance of excessive vibrations that can reduce the life of the microtool, even if it presents greater rigidity. Regarding the roughness, it was observed that the deflection of the microtool did not influence the surface finish, which was affected by the cutting speed. It was found that the average roughness (Ra) varied from 0.1241 to 0.3206 μm for all the cutting conditions used, and the highest roughness was obtained at the highest cutting speed. The top burrs presented larger dimensions, and the burrs on the down milling side are larger than the up milling side. These results demonstrate the important contribution of this work to the understanding of micromachining processes.

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Funding

This study is funded by the Brazilian research funding agencies CNPq (National Council for Scientific and Technological Development), CAPES (Coordination for the Improvement of Higher Education Personnel), and FAPEMIG (Minas Gerais State Research Foundation).

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Federal University of Uberlandia, Avenue João Naves de Ávila, 2121, Uberlandia, 38408-014, Brazil

    Milla Caroline Gomes, Márcio Bacci da Silva & Marcus Antonio Viana Duarte

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  1. Milla Caroline Gomes
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  2. Márcio Bacci da Silva
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  3. Marcus Antonio Viana Duarte
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Correspondence to Milla Caroline Gomes.

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Gomes, M.C., da Silva, M.B. & Duarte, M.A.V. Experimental study of micromilling operation of stainless steel. Int J Adv Manuf Technol 111, 3123–3139 (2020). https://doi.org/10.1007/s00170-020-06232-7

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