Skip to main content

Advertisement

SpringerLink
Log in

Fabrication and evaluation of micromill-grinding tools by electroplating CBN

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

Abstract

The micromill-grinding tool is a compound tool that has both micromilling and microgrinding abilities. Local electroplating was employed to fabricate micromill-grinding tools with CBN abrasive. The grits topography of the flank face was measured, and the graphical investigation was carried out to evaluate the distribution of the grits. It is found that the coatings were well electroplated and the abrasive grains were distributed more evenly on the 1.5-mm tool than on the 0.9-mm tool. The experiments were performed to evaluate the machining characteristics of the micromill-grinding tool. The machined surface roughness and the forces were measured, and the effects of processing parameters on surface roughness were analyzed. The tool wear style was investigated. The results show that the surface topography of micromill-grinding is similar to that of microgrinding. Under the same conditions, its surface roughness is better than that of micromilling, but worse than that of microgrinding. The grits on the tool flank face lead to the decrease of the normal force but the increase of the tangential force in machining. The wear style of micromill-grinding tool is mainly abrasive grain shedding.

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

Similar content being viewed by others

References

  1. Eberle G, Dold C, Wegener K (2015) Laser fabrication of diamond micro-cutting tool-related geometries using a high-numerical aperture micro-scanning system. Int J Adv Manuf Technol 1-9

  2. Lian H, Guo Z, Huang Z, Tang Y, Song J (2013) Experimental research of Al6061 on ultrasonic vibration assisted micro-milling. Procedia CIRP 6:561–564

    Article  Google Scholar 

  3. Choi SH, Ryu SH, Choi DK, Chu CN (2007) Fabrication of WC micro-shaft by using electrochemical etching. Int J Adv Manuf Technol 31(7-8):682–687

    Article  Google Scholar 

  4. Karthikeyan G, Ramkumar J, Dhamodaran S, Aravindan S (2010) Micro electric discharge milling process performance: an experimental investigation. Int J Mach Tools Manuf 50(8):718–727

    Article  Google Scholar 

  5. Zhang L, Du J, Zhuang X, Wang Z, Pei J (2015) Geometric prediction of conic tool in micro-EDM milling with fix-length compensation using simulation. Int J Mach Tools Manuf 89:86–94

    Article  Google Scholar 

  6. Cheng X, Wang ZG, Kobayashi S, Nakamoto K, Yamazaki K (2010) Tool fabrication system for micro/nano milling—function analysis and design of a six-axis Wire EDM machine. Int J Adv Manuf Technol 46(1-4):179–189

    Article  Google Scholar 

  7. Chae J, Park SS, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46(3):313–332

    Article  Google Scholar 

  8. Masuzawa T (2000) State of the art of micromachining. CIRP Annals-Manufacturing Technology 49(2):473–488

    Article  Google Scholar 

  9. Alting L, Kimura F, Hansen HN, Bissacco G (2003) Micro engineering. CIRP Annals-Manufacturing Technology 52(2):635–657

    Article  Google Scholar 

  10. Denkena B, Hoffmeister HW, Reichstein M, Illenseer S, Hlavac M (2006) Micro-machining processes for microsystem technology. Microsyst Technol 12(7):659–664

    Article  Google Scholar 

  11. Fleischer J, Masuzawa T, Schmidt J, Knoll M (2004) New applications for micro-EDM. J Mater Process Technol 149(1):246–249

    Article  Google Scholar 

  12. Yan J, Uchida K, Yoshihara N, Kuriyagawa T (2009) Fabrication of micro end mills by wire EDM and some micro cutting tests. J Micromech Microeng 19(2):025004

    Article  Google Scholar 

  13. Ali MY, Ong AS (2006) Fabricating micromilling tool using wire electrodischarge grinding and focused ion beam sputtering. Int J Adv Manuf Technol 31(5-6):501–508

    Article  Google Scholar 

  14. Egashira K, Hosono S, Takemoto S, Masao Y (2011) Fabrication and cutting performance of cemented tungsten carbide micro-cutting tools. Precision Engineering 35(4):547–553

    Article  Google Scholar 

  15. Adams DP, Vasile MJ, Benavides G, Campbell AN (2001) Micromilling of metal alloys with focused ion beam–fabricated tools. Precision Engineering 25(2):107–113

    Article  Google Scholar 

  16. Jain VK, Kalia S, Sidpara A, Kulkarni VN (2012) Fabrication of micro-features and micro-tools using electrochemical micromachining. Int J Adv Manuf Technol 61(9-12):1175–1183

    Article  Google Scholar 

  17. Fleischer J, Deuchert M, Ruhs C, Kühlewein C, Halvadjiysky G, Schmidt C (2008) Design and manufacturing of micro milling tools. Microsyst Technol 14(9-11):1771–1775

    Article  Google Scholar 

  18. Cheng X, Wang Z, Nakamoto K, Yamazaki K (2011) A study on the micro tooling for micro/nano milling. Int J Adv Manuf Technol 53(5-8):523–533

    Article  Google Scholar 

  19. Perveen A, San WY, Rahman M (2012) Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of BK7 glass. Int J Adv Manuf Technol 61(1-4):101–115

    Article  Google Scholar 

  20. Cheng X, Wang ZG, Nakamoto K, Yamazaki K (2009) Design and development of a micro polycrystalline diamond ball end mill for micro/nano freeform machining of hard and brittle materials. J Micromech Microeng 19(11):115022

    Article  Google Scholar 

  21. Ohnishi O, ONIKURA H, MIN SK, Aziz M, TSURUOKA S (2007) Characteristics of grooving by micro end mills with various tool shapes and approach to their optimal shape. Memoirs of the Faculty of Engineering, Kyushu University 67(4):143–151

    Google Scholar 

  22. Suzuki H, Moriwaki T, Yamamoto Y, Goto Y (2007) Precision cutting of aspherical ceramic molds with micro PCD milling tool. CIRP Annals-Manufacturing Technology 56(1):131–134

    Article  Google Scholar 

  23. Fang FZ, Wu H, Liu XD, Liu YC, Ng ST (2003) Tool geometry study in micromachining. J Micromech Microeng 13(5):726–731

    Article  Google Scholar 

  24. De Cristofaro S, Funaro N, Feriti GC, Rostagno M, Comoglio M, Merlo A, Dario P (2012) High-speed micro-milling: novel coatings for tool wear reduction. Int J Mach Tools Manuf 63:16–20

    Article  Google Scholar 

  25. Ritzhaupt-Kleissl E, Müller C, Sossalla A, Ertl S, Gluche P (2005) Fabrication of diamond micro tools for ultra precision machining. Microsyst Technol 11(4-5):278–279

    Article  Google Scholar 

  26. Torres CD, Heaney PJ, Sumant AV, Hamilton MA, Carpick RW, Pfefferkorn FE (2009) Analyzing the performance of diamond-coated micro end mills. Int J Mach Tools Manuf 49(7):599–612

    Article  Google Scholar 

  27. Chen ST, Lin SJ (2011) Development of an extremely thin grinding-tool for grinding microgrooves in optical glass. J Mater Process Technol 211(10):1581–1589

    Article  Google Scholar 

  28. Aurich JC, Engmann J, Schueler GM, Haberland R (2009) Micro grinding tool for manufacture of complex structures in brittle materials. CIRP Annals-Manufacturing Technology 58(1):311–314

    Article  Google Scholar 

  29. Gäbler J, Pleger S (2010) Precision and micro CVD diamond-coated grinding tools. Int J Mach Tools Manuf 50(4):420–424

    Article  Google Scholar 

  30. Ercoli C, Rotella M, Funkenbusch PD, Russell S, Feng C (2009) In vitro comparison of the cutting efficiency and temperature production of 10 different rotary cutting instruments. Part I: Turbine. The Journal of prosthetic dentistry 101(4):248–261

    Article  Google Scholar 

  31. Brinksmeier E, Orlik B, Groll R, Brandao C, Norbach A, Leach K (2013) GrindBall: an advanced micro-grinding tool. Production Engineering 7(5):469–476

    Article  Google Scholar 

  32. Biermann D, Feldhoff M (2012) Abrasive points for drill grinding of carbon fibre reinforced thermoset. CIRP Annals-Manufacturing Technology 61(1):299–302

    Article  Google Scholar 

  33. Rahman MA, Rahman M, Kumar AS, Lim HS, Asad ABMA (2006) Development of micropin fabrication process using tool based micromachining. Int J Adv Manuf Technol 27(9-10):939–944

    Article  Google Scholar 

  34. Butler-Smith PW, Axinte DA, Daine M (2012) Solid diamond micro-grinding tools: from innovative design and fabrication to preliminary performance evaluation in Ti–6Al–4V. Int J Mach Tools Manuf 59:55–64

    Article  Google Scholar 

  35. Chen M, Liu H, Su Y, Yu B, Fang Z (2015) Design and fabrication of a novel magnetorheological finishing process for small concave surfaces using small ball-end permanent-magnet polishing head. Int J Adv Manuf Technol 1-12

  36. Yao Y, Hao Z, Liu X (2014) Experimental study of machinability in mill-grinding of SiCp/Al composites. Journal of Wuhan University of Technology-Mater. Sci Ed 29(6):1104–1110

    Google Scholar 

  37. Du JG (2014) Research on mill-grinding and its key technology of SiC particle reinforced aluminum matrix composites., Doctoral dissertation, Harbin Institute of Technology

    Google Scholar 

  38. Ko TJ, Yoon IJ (2012) Mill-grinding with electroplated diamond abrasives for ceramic cutting. Int J Precis Eng Manuf 13(1):5–10

    Article  Google Scholar 

  39. Gong YD, Wen XL, Cheng J, Yin GQ, Wang C (2014) Experimental study on fabrication and evaluation of a micro-scale shaft grinding tool. J Mech Sci Technol 28(3):1027–1037

    Article  Google Scholar 

  40. Wang C, Gong YD, Yin GQ, Wen XL, Cheng J (2013) Study on micro mill-grinding technology. Applied Mechanics and Materials 390:586–590

    Article  Google Scholar 

  41. Wang C, Gong YD, Yin GQ, Cheng J (2013) Influence of tool diameter and abrasive particle size on surface roughness in micro mill-grinding. Journal of Northeastern University (Natural Science) 34(12):1759–1762

    Google Scholar 

  42. Cheng J, Gong YD (2013) Experimental study on ductile-regime micro-grinding character of soda-lime glass with diamond tool. Int J Adv Manuf Technol 69(1-4):147–160

    Article  Google Scholar 

  43. Stout KJ, Blunt L (2000) Visualization techniques and parameters for characterizing three-dimensional surface topography. Heinemann Press, Butterworth

    Google Scholar 

  44. Qiao G, Dong G, Zhou M (2013) Simulation and assessment of diamond mill grinding wheel topography. Int J Adv Manuf Technol 68(9-12):2085–2093

    Article  Google Scholar 

  45. Yan L, Rong YM, Jiang F, Zhou ZX (2011) Three-dimension surface characterization of grinding wheel using white light interferometer. Int J Adv Manuf Technol 55(1-4):133–141

    Article  Google Scholar 

  46. Blunt L, Ebdon S (1996) The application of three-dimensional surface measurement techniques to characterizing grinding wheel topography. Int J Mach Tools Manuf 36(11):1207–1226

    Article  Google Scholar 

  47. Tahvilian AM, Liu Z, Champliaud H, Hazel B, Lagacé M (2015) Characterization of grinding wheel grain topography under different robotic grinding conditions using confocal microscope. Int J Adv Manuf Technol 1-13

  48. Li X, Wolf S, Zhi G, Rong Y (2014) The modelling and experimental verification of the grinding wheel topographical properties based on the ‘through-the-process’ method. Int J Adv Manuf Technol 70(1-4):649–659

    Article  Google Scholar 

  49. Mijušković G, Krajnik P, Kopač J (2015) Analysis of tool deflection in micro milling of graphite electrodes. Int J Adv Manuf Technol 76(1-4):209–217

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Institute of Advanced Manufacturing and Automation Technology, Northeastern University, Shenyang, 110819, China

    Chao Wang, Yadong Gong, Jun Cheng, Xuelong Wen & Yunguang Zhou

Authors
  1. Chao Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yadong Gong
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jun Cheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xuelong Wen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yunguang Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chao Wang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, C., Gong, Y., Cheng, J. et al. Fabrication and evaluation of micromill-grinding tools by electroplating CBN. Int J Adv Manuf Technol 87, 3513–3526 (2016). https://doi.org/10.1007/s00170-016-8730-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-8730-1

Keywords

Search

Navigation