Skip to main content
SpringerLink
Log in

Experimental investigation of tool deflection in micro-milling of fine-grained graphite

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The micro-milling process is one of the most suitable methods for the accurate machining of devices in the micro-domain and is implemented for a wide range of materials. Fine-grained graphite is extensively used as electrode material for micro-electrical discharge machining because of its excellent thermal, chemical, and electrical properties. Dimensional accuracy and form accuracy are among main goals in the micro-milling process of the 3D micro-form electrodes. Among the numerous factors that affect the quality of the machined micro-components, tool deflection is the most significant. This paper investigates the influence of fine-grained graphite type, depth of cut, tool wear, cutting edge radius size, workpiece inclination angle, and machining strategy as control factors on tool deflection. The experimental results presented in this paper provide important insight into tool deflection issues for improving machining accuracy in micro-milling process of graphite electrodes with complex 3D geometry and high aspect ratio.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Data Availability

Not applicable.

Code availability

Not applicable.

References

  1. Huo D, Cheng K (2013) Overview of micro cutting. In: Cheng K, Huo D (eds) Micro-cutting: fundamentals and applications. John Wiley & Sons, Chichester, pp 1–17

    Google Scholar 

  2. O’Toole L, Kang CW, Fang FZ (2021) Precision micro-milling process: state of the art. Adv Manuf 9:173–205. https://doi.org/10.1007/s40436-020-00323-0

    Article  Google Scholar 

  3. Câmara MA, Rubio JCC, Abrão AM, Davim JP (2012) State of the art on micromilling of materials, a review. J Mater Sci Technol 28:673–685. https://doi.org/10.1016/S1005-0302(12)60115-7

    Article  Google Scholar 

  4. Serje D, Pacheco J, Diez E (2020) Micromilling research: current trends and future prospects. Int J Adv Manuf Technol 111:1889–1916. https://doi.org/10.1007/s00170-020-06205-w

    Article  Google Scholar 

  5. Balázs BZ, Geier N, Takács M, Davim JP (2021) A review on micro-milling: recent advances and future trends. Int J Adv Manuf Technol 112:655–684. https://doi.org/10.1007/s00170-020-06445-w

    Article  Google Scholar 

  6. Uriarte L, Eguía J, Egaña F (2009) Micro-milling machines. In: Lamikiz A (ed) López de Lacalle LN. Machine tools for high performance machining. Springer, London, pp 369–397

    Google Scholar 

  7. Uriarte L, Herrero A, Zatarain M, Santiso G, Lopéz de Lacalle LN, Lamikiz A, Albizuri J (2007) Error budget and stiffness chain assessment in a micro-milling machine equipped with tools less than 0.3 mm in diameter. Precis Eng 31:1–12. https://doi.org/10.1016/j.precisioneng.2005.11.010

    Article  Google Scholar 

  8. Wu T, Cheng K, Rakowski R (2012) Investigation on tooling geometrical effects of micro tools and the associated micro milling performance. Proc Inst Mech Eng B: J Eng Manuf 226:1442–1453. https://doi.org/10.1177/0954405412449229

    Article  Google Scholar 

  9. Oliaei SNB, Karpat Y (2016) Influence of tool wear on machining forces and tool deflections during micro milling. Int J Adv Manuf Technol 84:1963–1980. https://doi.org/10.1007/s00170-015-7744-4

    Article  Google Scholar 

  10. Mamedov A, Layegh EK, Lazoglu I (2015) Instantaneous tool deflection model for micro milling. Int J Adv Manuf Technol 79:769–777. https://doi.org/10.1007/s00170-015-6877-9

    Article  Google Scholar 

  11. Huo D, Chen W, Teng X, Lin C, Yang K (2017) Modeling the influence of tool deflection on cutting force and surface generation in micro-milling. Micromachines 8:188. https://doi.org/10.3390/mi8060188

    Article  Google Scholar 

  12. Moges TM, Desai KA, Rao PVM (2018) Modeling of cutting force, tool deflection, and surface error in micro-milling operation. Int J Adv Manuf Technol 98:2865–2881. https://doi.org/10.1007/s00170-018-2415-x

    Article  Google Scholar 

  13. Yuan M, Wang X, Jiao L, Yi J, Liu S (2017) Prediction of dimension error based on the deflection of cutting tool in micro ball-end milling. Int J Adv Manuf Technol 93:825–837. https://doi.org/10.1007/s00170-017-0474-z

    Article  Google Scholar 

  14. Zhang X, Yu T, Wang W (2018) Prediction of cutting forces and instantaneous tool deflection in micro end milling by considering tool run-out. Int J Mech Sci 136:124–133. https://doi.org/10.1016/j.ijmecsci.2017.12.019

    Article  Google Scholar 

  15. Rodríguez P, Labarga JE (2015) Tool deflection model for micromilling processes. Int J Adv Manuf Technol 76:199–207. https://doi.org/10.1007/s00170-014-5890-8

    Article  Google Scholar 

  16. Dow TA, Miller EL, Garrard K (2004) Tool force and deflection compensation for small milling tools. Precis Eng 28:31–45. https://doi.org/10.1016/S0141-6359(03)00072-2

    Article  Google Scholar 

  17. Biermann D, Kahnis P (2010) Analysis and simulation of size effects in micromilling. Prod Eng 4:25–34. https://doi.org/10.1007/s11740-009-0201-1

    Article  Google Scholar 

  18. Heo S, Lee M, Kim SH, Lee W, Min B-K (2015) Compensation of tool deflection in micromilling using workpiece holder control device. Int J Precis Eng Manuf 16:1205–1208. https://doi.org/10.1007/s12541-015-0155-5

    Article  Google Scholar 

  19. Uriarte L, Azcarate S, Herrero A, Lopez de Lacalle LN, Lamikiz A (2008) Mechanistic modelling of the micro end milling operation. Proc Inst Mech Eng B J Eng Manuf 222:23–33. https://doi.org/10.1243/09544054JEM837

    Article  Google Scholar 

  20. Mijušković G, Krajnik P, Kopač J (2015) Analysis of tool deflection in micro milling of graphite electrodes. Int J Adv Manuf Technol 76:209–217. https://doi.org/10.1007/s00170-013-5536-2

    Article  Google Scholar 

  21. Wang CY, Zhou L, Fu H, Hu ZL (2007) High-speed milling of graphite electrode with small diameter endmill. Chin J Mech Eng 20:27–31. https://doi.org/10.3901/CJME.2007.04.027

    Article  Google Scholar 

  22. Zhou L, Wang CY, Qin Z (2009) Tool wear characteristics in high-speed milling of graphite using a coated carbide micro endmill. Proc Inst Mech Eng B J Eng Manuf 223:267–277. https://doi.org/10.1243/09544054JEM1326

    Article  Google Scholar 

  23. Zhou L, Wang CY, Qin Z, Li WH (2004) Wear characteristics of micro-end mill in high speed milling of graphite electrode. Key Eng Mater 259–260:858–863. https://doi.org/10.4028/www.scientific.net/KEM.259-260.858

    Article  Google Scholar 

  24. Huo D, Lin C, Dalgarno K (2014) An experimental investigation on micro machining of fine-grained graphite. Int J Adv Manuf Technol 72:943–953. https://doi.org/10.1007/s00170-014-5730-x

    Article  Google Scholar 

  25. Qiu H, Kubo A (2020) An experimental research on surface roughness of fine-grained graphite machined by micro end mills. J Inst Ind Appl Eng 8:95–103. https://doi.org/10.12792/jiiae.8.95

  26. Mijušković G, Dj C (2021) Investigation, modeling, and optimization of surface roughness in micro-milling of graphite electrodes. Int J Adv Manuf Technol 117:579–590. https://doi.org/10.1007/s00170-021-07762-4

    Article  Google Scholar 

  27. Konig M (1998) Frasbearbeitung von graphitelektroden. Dissertation RWTH Aachen University

  28. López de Lacalle LN, Lamikiz A, Sanchez JA, Salgado MA (2004) Effects of tool deflection in the high-speed milling of inclined surfaces. Int J Adv Manuf Technol 24:621–631. https://doi.org/10.1007/s00170-003-1723-x

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Faculty of Mechanical Engineering, University of Banja Luka, Banja Luka, Bosnia and Herzegovina

    Djordje Cica & Branislav Sredanovic

  2. Faculty of Mechanical Engineering, University of Ljubljana, Ljubljana, Slovenia

    Goran Mijušković

Authors
  1. Djordje Cica
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Branislav Sredanovic
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Goran Mijušković
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Not applicable.

Corresponding author

Correspondence to Djordje Cica.

Ethics declarations

Ethics approval

This paper is our original work and it has not been published elsewhere.

Consent to participate

All authors were fully involved in the study and each of the authors has agreed to participate in this study.

Consent for publication

All authors consent to publish the content in the final manuscript.

Conflict of interest

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

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Cica, D., Sredanovic, B. & Mijušković, G. Experimental investigation of tool deflection in micro-milling of fine-grained graphite. Int J Adv Manuf Technol 123, 161–168 (2022). https://doi.org/10.1007/s00170-022-10185-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10185-4

Keywords

Search

Navigation