Abstract
In the forming grinding of a cemented carbide micro-drill, edge burrs are generated. To explore the formation of the edge burrs, the grinding parameters, such as feed rate, grinding depth, wheel service time, and wheel rotation, are analyzed experimentally. Results show that the burrs on the micro-drill edge are caused by material plastic flow and cumulative effect of deformation under the grinding wheel cutting edge. At the same time, the greater the grinding depth, the greater the material flow and accumulation, and the bigger the edge burrs. When decreasing the feed rate to the grinding wheel, the number of grinding cycles will be increased, and the material accumulation on the micro-drill edge can be removed timeously by abrasive particles. This brought considerable relief in edge burr formation. The grinding wheel turning direction has a significant effect on material plastic deformation and its flowing. The cutting angle of abrasive particles is an acute angle when the grinding wheel rotates clockwise, much material accumulates near the blade, and the edge burrs on the blade are bigger. The cutting angle of an abrasive particle is obtuse when the grinding wheel rotates anticlockwise. The material is gathered towards the back face and departs from the micro-drill with no edge burrs being generated. When the grinding wheel is sharp, there are no distinct edge burrs generated. The results also show that, after grinding for 72 h, the edge burrs are generated as the sharpness decreases: the longer the grinding wheel is used, the bigger the edge burrs.
Similar content being viewed by others
Data availability
All authors have been personally and actively involved in substantive work leading to the report, and will hold themselves jointly and individually responsible for its content.
References
Shi HY, Li H (2013) Challenges and developments of micro drill bit for printed circuit board: a review. Circuit World 39(2):75–81. https://doi.org/10.1108/03056121311315792
Zheng LJ, Wang CY, Song YX, Yang LP, Qu YP, Ma P, Fu LY (2011) A review on drilling printed circuit boards. Adv Mater Res 188:44–449. https://doi.org/10.4028/www.scientific.net/AMR.188.441
Gao P, Liang ZQ, Wang XB, Zhou TF, Li SD, Zhang SY, Liu ZB (2017) Cutting edge damage in grinding of cemented carbides micro end mills. Ceram Int 43(14):11331–11338. https://doi.org/10.1016/j.ceramint.2017.05.336
Hoang TD, Nguyen VD, Nguyen HA, Nguyen NK, Hoang T, Nguyen DT (2020) Size effect of drill bit on coupled vibrations during high speed micro-drilling process of composite printed circuit board. Mater Sci Forum 975:217–222. https://doi.org/10.4028/www.scientific.net/MSF.975.217
Huang CK, Tarng YS, Chiu CY, Huang AP (2009) Investigation of machine vision assisted automatic resharpening process of micro-drills. J Mater Process Technol 209(18-19):5944–5954. https://doi.org/10.1016/j.jmatprotec.2009.07.013
Fang ZZ, Wang X, Ryu T, Hwang KS, Sohn HY (2009) Synthesis, sintering, and mechanical properties of nanocrystalline cemented tungsten carbide–a review. Int J Refract Met Hard Mater 27(2):288–299. https://doi.org/10.1016/j.ijrmhm.2008.07.011
Egashira K, Hosono S, Takemoto S, Masao Y (2011) Fabrication and cutting performance of cemented tungsten carbide micro-cutting tools. Precis Eng 35(4):547–553. https://doi.org/10.1016/j.precisioneng.2011.06.002
Liu K, Li XP, Rahman M (2003) Characteristics of high speed micro-cutting of tungsten carbide. J Mater Process Technol 140(1-3):352–357. https://doi.org/10.1016/S0924-0136(03)00758-1
Liang ZQ, Jian HC, Wang XB, Zhao WX, Zhang SY, Otani YS, Xue SY (2014) A 5-axis coordinated CNC grinding method for the flank of a non-coaxial helical micro-drill with the cylinder grinding wheel. Adv Mater Res 1017:654–659. https://doi.org/10.4028/www.scientific.net/AMR.1017.654
Zhang SY, Liang ZQ, Wang XB, Zhou TF, Li J, Yan P, JianH C (2016) Grinding process of helical micro-drill using a six-axis CNC grinding machine and its fundamental drilling performance. Int J Adv Manuf Technol 86(9-12):2823–2835. https://doi.org/10.1007/s00170-016-8359-0
Gao CC, Cheng J, Wu J (2019) Experimental study of metal ceramic (WC-Co) micro-tool fabrication by controlled inclined grinding (CIG). Int J Adv Manuf Technol 103(5-8):2151–2167. https://doi.org/10.1007/s00170-019-03658-6
Lee PH, Nam JS, Li CJ, Lee SW (2012) An experimental study on micro-grinding process with nanofluid minimum quantity lubrication (MQL). Int J Precis Eng Manuf 13(3):331–338. https://doi.org/10.1007/s12541-012-0042-2
Smith PB, Warhanek M, Axinte D, Fay M, Jean FB, Raphael R, Konrad W (2016) The influences of pulsed-laser-ablation and electro-discharge-grinding processes on the cutting performances of polycrystalline diamond micro-drills. CIRP Ann Manuf Technol 65(1):105–108. https://doi.org/10.1016/j.cirp.2016.04.008
Liu JD, Yuan W, Xiong JK, Xu ZL, Huang SW (2012) Study on the two-side direction burr in grinding-hardening machine based on orthogonal experimental method. Appl Mech Mater 217-219:1869–1873. https://doi.org/10.4028/www.scientific.net/AMM.217-219.1869
Liu GY, Dang JQ, Chen YF, Dong DP, An QL (2019) Numerical and experimental investigation on grinding-induced exit burr formation. Int J Adv Manuf Technol 103(5-8):2331–2346. https://doi.org/10.1007/s00170-019-03641-1
Zheng XH, Liu ZQ, Wang CY, An QL, Chen M (2012) Experimental research on micro burrs of high speed drilling of PCB using microdrill. Adv Mater Res 497:215–219. https://doi.org/10.4028/www.scientific.net/AMR.497.215
Zheng XH, Dong DP, Huang LX, Wang XB, Chen M (2013) Investigation of tool wear mechanism and tool geometry optimization in drilling of PCB fixture hole. Circuit World 2013 39(4):195–203. https://doi.org/10.1108/cw-06-2013-0021
Dong DP, Song JB, Yu DD, Chen M (2017) Finite element analysis of burr formation and an automatic online micro-deburring method in precise end-face grinding process. Proc Inst Mech Eng B J Eng Manuf 231(14):2495–2503. https://doi.org/10.1177/0954405415617927
Liu C, Lin N, He YH, Wu CH, Jiang Y (2014) The effects of micron WC contents on the microstructure and mechanical properties of ultrafine WC–(micron WC–Co) cemented carbides. J Alloys Compd 594:76–81. https://doi.org/10.1016/j.jallcom.2014.01.090
Packeisen A, Theisen W (1999) Turning and grinding of hard alloys. Adv Eng Mater 1(1):35–48. https://doi.org/10.1002/(SICI)1527-2648(199909)1:1<35:AID-ADEM35>3.0.CO;2-W
Zhang QL, Guo N, Chen Y, Suet T (2019) Effects of binder concentration on the nanometric surface characteristics of WC-Co materials in ultra-precision grinding. Int J Refract Met Hard Mater 85:105048. https://doi.org/10.1016/j.ijrmhm.2019.105048
Bhandari B, Hong YS, Yoon HS, Moona JS, Minh QP, Lee GB, Huang YC (2014) Development of a micro-drilling burr-control chart for PCB drilling. Precis Eng 38(1):221–229. https://doi.org/10.1016/j.precisioneng.2013.07.010
Hasan M, Zhao JW, Jiang ZY (2017) A review of modern advancements in micro drilling techniques. J Manuf Process 29:343–375. https://doi.org/10.1016/j.jmapro.2017.08.006
Wang LF, Zheng LJ, Wang CY, Song YX, Zhang LQ, Sun P (2014) Experimental study on micro-drills wear during high speed of drilling IC substrate. Circuit World 40(2):61–70. https://doi.org/10.1108/CW-11-2013-0048
Cristofaro DS, Funaro N, Feriti GC, Rostagno M, Comoglio M, Merlo A, Stefanini C, Dario P (2012) High-speed micro-milling: novel coatings for tool wear reduction. Int J Mach Tool Manu 63:16–20. https://doi.org/10.1016/j.ijmachtools.2012.07.005
Wang RX, Zhou K, Yang JY, Ding HZH, Wang WJ, Guo J, Liu QY (2020) Effects of abrasive material and hardness of grinding wheel on rail grinding behaviors. Wear 454-455:203332. https://doi.org/10.1016/j.wear.2020.203332
Wang ZK, Zhu Y, Zhu YW, Su JX (2015) Effect of lapping slurry on critical cutting depth of spinel. Appl Surf Sci 347:849–855. https://doi.org/10.1016/j.apsusc.2015.04.092
Anstis GR, Chantikul P, Lawn BR, Marshall DB (1981) A critical evaluation of indentation techniques for measuring fracture toughness: I, direct crack measurements. Appl Surf Sci 64(9):533–538. https://doi.org/10.1111/j.1151-2916.1981.tb10320.x
Funding
This paper is supported by the Guangzhou Science and Technology Project (No. 201904010300).
Author information
Authors and Affiliations
Contributions
Qiang Xiong: investigation, software, data curation, writing—original draft preparation.
Qiusheng Yan: funding acquisition, visualization.
Jiabin Lu: methodology, formal analysis, conceptualization.
Jisheng Pan: funding acquisition.
Corresponding author
Ethics declarations
Ethical approval
1. The material has not been published in whole or in part elsewhere;
2. The paper is not currently being considered for publication elsewhere.
Consent to participate
The author hopes that this paper can be applied to the International Journal of Advanced Manufacturing Technology.
Consent to publish
The authors agree to be published in the International Journal of Advanced Manufacturing Technology.
Competing interests
The authors declare no competing interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Xiong, Q., Yan, Q., Lu, J. et al. The effects of grinding process parameters of a cemented carbide micro-drill on cutting edge burr formation. Int J Adv Manuf Technol 117, 3041–3051 (2021). https://doi.org/10.1007/s00170-021-07662-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-07662-7