Investigation on self-fabricated PCD cutter and its application in deep-and-narrow micro-grooves
Micro-milling cutter is a critical enabling technology in manufacturing of miniaturized components with sufficient geometrical accuracy and surface integrity, particularly for the high aspect ratio micro-structures. Super-hard diamond micro-milling cutter has exceptional performance compared with co...
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| Veröffentlicht in: | International journal of advanced manufacturing technology 2022-04, Vol.119 (9-10), p.6743-6760 |
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| container_title | International journal of advanced manufacturing technology |
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| creator | Han, Jinjin Ma, Rui Kong, Linglei He, Bin Hao, Xiuqing He, Qing Li, Liang He, Ning |
| description | Micro-milling cutter is a critical enabling technology in manufacturing of miniaturized components with sufficient geometrical accuracy and surface integrity, particularly for the high aspect ratio micro-structures. Super-hard diamond micro-milling cutter has exceptional performance compared with conventional cemented carbide micro-milling cutter. However, the preparation of polycrystalline diamond (PCD) micro-milling cutter with large aspect ratio (LAR) is still a major challenge due to its low stiffness, high hardness, and long cutting-edge. In this paper, LAR PCD micro-milling cutter was fabricated through a hybrid approach by combining the pulsed nanosecond laser with precision grinding. Then experimental verifications were carried out on Oxygen-Free Copper material. The machined surface quality, burr formation, and tool wear were investigated through parametric and deep-and-narrow micro-groove experiments. The results confirmed that the self-fabricated PCD cutter could obtain micro-grooves with nano-surface roughness (less than 100 nm), homogeneous bottom surface, and nearly burr-free top surfaces (3 ~ 6 μm). The PCD cutter exhibited high wear resistance and edge sharpness retention in machining of 1.0-mm-depth micro-groove. Furthermore, multi-cycle deep-and-narrow micro-grooves were manufactured by self-fabricated PCD cutter, and the machined quality was proved to be predominant. |
| doi_str_mv | 10.1007/s00170-022-08692-5 |
| format | Article |
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Super-hard diamond micro-milling cutter has exceptional performance compared with conventional cemented carbide micro-milling cutter. However, the preparation of polycrystalline diamond (PCD) micro-milling cutter with large aspect ratio (LAR) is still a major challenge due to its low stiffness, high hardness, and long cutting-edge. In this paper, LAR PCD micro-milling cutter was fabricated through a hybrid approach by combining the pulsed nanosecond laser with precision grinding. Then experimental verifications were carried out on Oxygen-Free Copper material. The machined surface quality, burr formation, and tool wear were investigated through parametric and deep-and-narrow micro-groove experiments. The results confirmed that the self-fabricated PCD cutter could obtain micro-grooves with nano-surface roughness (less than 100 nm), homogeneous bottom surface, and nearly burr-free top surfaces (3 ~ 6 μm). The PCD cutter exhibited high wear resistance and edge sharpness retention in machining of 1.0-mm-depth micro-groove. Furthermore, multi-cycle deep-and-narrow micro-grooves were manufactured by self-fabricated PCD cutter, and the machined quality was proved to be predominant.</description><identifier>ISSN: 0268-3768</identifier><identifier>EISSN: 1433-3015</identifier><identifier>DOI: 10.1007/s00170-022-08692-5</identifier><language>eng</language><publisher>London: Springer London</publisher><subject>Accuracy ; Advanced manufacturing technologies ; CAE) and Design ; Cemented carbides ; Comminution ; Computer-Aided Engineering (CAD ; Diamond machining ; Efficiency ; Engineering ; Experiments ; Geometric accuracy ; Grooves ; High aspect ratio ; Industrial and Production Engineering ; Lasers ; Manufacturing ; Mechanical Engineering ; Media Management ; Milling (machining) ; Original Article ; Polycrystalline diamond ; Stiffness ; Surface properties ; Surface roughness ; Tool wear ; Wear resistance</subject><ispartof>International journal of advanced manufacturing technology, 2022-04, Vol.119 (9-10), p.6743-6760</ispartof><rights>The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2022</rights><rights>The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2022.</rights><lds50>peer_reviewed</lds50><woscitedreferencessubscribed>false</woscitedreferencessubscribed><citedby>FETCH-LOGICAL-c319t-2486a6bc09908fd2ce6378f58e6646f0e853f937c4e0d91e1d786991c703fbc93</citedby><cites>FETCH-LOGICAL-c319t-2486a6bc09908fd2ce6378f58e6646f0e853f937c4e0d91e1d786991c703fbc93</cites></display><links><openurl>$$Topenurl_article</openurl><openurlfulltext>$$Topenurlfull_article</openurlfulltext><thumbnail>$$Tsyndetics_thumb_exl</thumbnail><linktopdf>$$Uhttps://link.springer.com/content/pdf/10.1007/s00170-022-08692-5$$EPDF$$P50$$Gspringer$$H</linktopdf><linktohtml>$$Uhttps://link.springer.com/10.1007/s00170-022-08692-5$$EHTML$$P50$$Gspringer$$H</linktohtml><link.rule.ids>314,777,781,27905,27906,41469,42538,51300</link.rule.ids></links><search><creatorcontrib>Han, Jinjin</creatorcontrib><creatorcontrib>Ma, Rui</creatorcontrib><creatorcontrib>Kong, Linglei</creatorcontrib><creatorcontrib>He, Bin</creatorcontrib><creatorcontrib>Hao, Xiuqing</creatorcontrib><creatorcontrib>He, Qing</creatorcontrib><creatorcontrib>Li, Liang</creatorcontrib><creatorcontrib>He, Ning</creatorcontrib><title>Investigation on self-fabricated PCD cutter and its application in deep-and-narrow micro-grooves</title><title>International journal of advanced manufacturing technology</title><addtitle>Int J Adv Manuf Technol</addtitle><description>Micro-milling cutter is a critical enabling technology in manufacturing of miniaturized components with sufficient geometrical accuracy and surface integrity, particularly for the high aspect ratio micro-structures. Super-hard diamond micro-milling cutter has exceptional performance compared with conventional cemented carbide micro-milling cutter. However, the preparation of polycrystalline diamond (PCD) micro-milling cutter with large aspect ratio (LAR) is still a major challenge due to its low stiffness, high hardness, and long cutting-edge. In this paper, LAR PCD micro-milling cutter was fabricated through a hybrid approach by combining the pulsed nanosecond laser with precision grinding. Then experimental verifications were carried out on Oxygen-Free Copper material. The machined surface quality, burr formation, and tool wear were investigated through parametric and deep-and-narrow micro-groove experiments. The results confirmed that the self-fabricated PCD cutter could obtain micro-grooves with nano-surface roughness (less than 100 nm), homogeneous bottom surface, and nearly burr-free top surfaces (3 ~ 6 μm). The PCD cutter exhibited high wear resistance and edge sharpness retention in machining of 1.0-mm-depth micro-groove. Furthermore, multi-cycle deep-and-narrow micro-grooves were manufactured by self-fabricated PCD cutter, and the machined quality was proved to be predominant.</description><subject>Accuracy</subject><subject>Advanced manufacturing technologies</subject><subject>CAE) and Design</subject><subject>Cemented carbides</subject><subject>Comminution</subject><subject>Computer-Aided Engineering (CAD</subject><subject>Diamond machining</subject><subject>Efficiency</subject><subject>Engineering</subject><subject>Experiments</subject><subject>Geometric accuracy</subject><subject>Grooves</subject><subject>High aspect ratio</subject><subject>Industrial and Production Engineering</subject><subject>Lasers</subject><subject>Manufacturing</subject><subject>Mechanical Engineering</subject><subject>Media Management</subject><subject>Milling (machining)</subject><subject>Original Article</subject><subject>Polycrystalline diamond</subject><subject>Stiffness</subject><subject>Surface properties</subject><subject>Surface roughness</subject><subject>Tool wear</subject><subject>Wear resistance</subject><issn>0268-3768</issn><issn>1433-3015</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2022</creationdate><recordtype>article</recordtype><sourceid>AFKRA</sourceid><sourceid>BENPR</sourceid><sourceid>CCPQU</sourceid><sourceid>DWQXO</sourceid><recordid>eNp9UMtKAzEUDaJgrf6Aq4Dr6E0yk8dS6hMKutB1TDNJSWlnxmSq-PdmHMGdcOEuzuPecxA6p3BJAeRVBqASCDBGQAnNSH2AZrTinHCg9SGaAROKcCnUMTrJeVPoggo1Q2-P7YfPQ1zbIXYtLpP9NpBgVyk6O_gGPy9usNsPg0_Ytg2OQ8a277cjOipiixvve1Iw0tqUuk-8iy51ZJ26rlifoqNgt9mf_e45er27fVk8kOXT_ePiekkcp3ogrFLCipUDrUGFhjkvuFShVl6ISgTwquZBc-kqD42mnjay5NTUSeBh5TSfo4vJt0_d-75EMptun9py0jBRMQqCViOLTazyYc7JB9OnuLPpy1AwY5NmatKUJs1Pk6YuIj6JciG3a5_-rP9RfQM-xXZY</recordid><startdate>20220401</startdate><enddate>20220401</enddate><creator>Han, Jinjin</creator><creator>Ma, Rui</creator><creator>Kong, Linglei</creator><creator>He, Bin</creator><creator>Hao, Xiuqing</creator><creator>He, Qing</creator><creator>Li, Liang</creator><creator>He, Ning</creator><general>Springer London</general><general>Springer Nature B.V</general><scope>AAYXX</scope><scope>CITATION</scope><scope>8FE</scope><scope>8FG</scope><scope>ABJCF</scope><scope>AFKRA</scope><scope>BENPR</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>DWQXO</scope><scope>HCIFZ</scope><scope>L6V</scope><scope>M7S</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PRINS</scope><scope>PTHSS</scope></search><sort><creationdate>20220401</creationdate><title>Investigation on self-fabricated PCD cutter and its application in deep-and-narrow micro-grooves</title><author>Han, Jinjin ; Ma, Rui ; Kong, Linglei ; He, Bin ; Hao, Xiuqing ; He, Qing ; Li, Liang ; He, Ning</author></sort><facets><frbrtype>5</frbrtype><frbrgroupid>cdi_FETCH-LOGICAL-c319t-2486a6bc09908fd2ce6378f58e6646f0e853f937c4e0d91e1d786991c703fbc93</frbrgroupid><rsrctype>articles</rsrctype><prefilter>articles</prefilter><language>eng</language><creationdate>2022</creationdate><topic>Accuracy</topic><topic>Advanced manufacturing technologies</topic><topic>CAE) and Design</topic><topic>Cemented carbides</topic><topic>Comminution</topic><topic>Computer-Aided Engineering (CAD</topic><topic>Diamond machining</topic><topic>Efficiency</topic><topic>Engineering</topic><topic>Experiments</topic><topic>Geometric accuracy</topic><topic>Grooves</topic><topic>High aspect ratio</topic><topic>Industrial and Production Engineering</topic><topic>Lasers</topic><topic>Manufacturing</topic><topic>Mechanical Engineering</topic><topic>Media Management</topic><topic>Milling (machining)</topic><topic>Original Article</topic><topic>Polycrystalline diamond</topic><topic>Stiffness</topic><topic>Surface properties</topic><topic>Surface roughness</topic><topic>Tool wear</topic><topic>Wear resistance</topic><toplevel>peer_reviewed</toplevel><toplevel>online_resources</toplevel><creatorcontrib>Han, Jinjin</creatorcontrib><creatorcontrib>Ma, Rui</creatorcontrib><creatorcontrib>Kong, Linglei</creatorcontrib><creatorcontrib>He, Bin</creatorcontrib><creatorcontrib>Hao, Xiuqing</creatorcontrib><creatorcontrib>He, Qing</creatorcontrib><creatorcontrib>Li, Liang</creatorcontrib><creatorcontrib>He, Ning</creatorcontrib><collection>CrossRef</collection><collection>ProQuest SciTech Collection</collection><collection>ProQuest Technology Collection</collection><collection>Materials Science & Engineering Collection</collection><collection>ProQuest Central UK/Ireland</collection><collection>ProQuest Central</collection><collection>Technology Collection</collection><collection>ProQuest One Community College</collection><collection>ProQuest Central Korea</collection><collection>SciTech Premium Collection</collection><collection>ProQuest Engineering Collection</collection><collection>Engineering Database</collection><collection>ProQuest One Academic Eastern Edition (DO NOT USE)</collection><collection>ProQuest One Academic</collection><collection>ProQuest One Academic UKI Edition</collection><collection>ProQuest Central China</collection><collection>Engineering Collection</collection><jtitle>International journal of advanced manufacturing technology</jtitle></facets><delivery><delcategory>Remote Search Resource</delcategory><fulltext>fulltext</fulltext></delivery><addata><au>Han, Jinjin</au><au>Ma, Rui</au><au>Kong, Linglei</au><au>He, Bin</au><au>Hao, Xiuqing</au><au>He, Qing</au><au>Li, Liang</au><au>He, Ning</au><format>journal</format><genre>article</genre><ristype>JOUR</ristype><atitle>Investigation on self-fabricated PCD cutter and its application in deep-and-narrow micro-grooves</atitle><jtitle>International journal of advanced manufacturing technology</jtitle><stitle>Int J Adv Manuf Technol</stitle><date>2022-04-01</date><risdate>2022</risdate><volume>119</volume><issue>9-10</issue><spage>6743</spage><epage>6760</epage><pages>6743-6760</pages><issn>0268-3768</issn><eissn>1433-3015</eissn><abstract>Micro-milling cutter is a critical enabling technology in manufacturing of miniaturized components with sufficient geometrical accuracy and surface integrity, particularly for the high aspect ratio micro-structures. Super-hard diamond micro-milling cutter has exceptional performance compared with conventional cemented carbide micro-milling cutter. However, the preparation of polycrystalline diamond (PCD) micro-milling cutter with large aspect ratio (LAR) is still a major challenge due to its low stiffness, high hardness, and long cutting-edge. In this paper, LAR PCD micro-milling cutter was fabricated through a hybrid approach by combining the pulsed nanosecond laser with precision grinding. Then experimental verifications were carried out on Oxygen-Free Copper material. The machined surface quality, burr formation, and tool wear were investigated through parametric and deep-and-narrow micro-groove experiments. The results confirmed that the self-fabricated PCD cutter could obtain micro-grooves with nano-surface roughness (less than 100 nm), homogeneous bottom surface, and nearly burr-free top surfaces (3 ~ 6 μm). The PCD cutter exhibited high wear resistance and edge sharpness retention in machining of 1.0-mm-depth micro-groove. Furthermore, multi-cycle deep-and-narrow micro-grooves were manufactured by self-fabricated PCD cutter, and the machined quality was proved to be predominant.</abstract><cop>London</cop><pub>Springer London</pub><doi>10.1007/s00170-022-08692-5</doi><tpages>18</tpages></addata></record> |
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| subjects | Accuracy Advanced manufacturing technologies CAE) and Design Cemented carbides Comminution Computer-Aided Engineering (CAD Diamond machining Efficiency Engineering Experiments Geometric accuracy Grooves High aspect ratio Industrial and Production Engineering Lasers Manufacturing Mechanical Engineering Media Management Milling (machining) Original Article Polycrystalline diamond Stiffness Surface properties Surface roughness Tool wear Wear resistance |
| title | Investigation on self-fabricated PCD cutter and its application in deep-and-narrow micro-grooves |
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