Defining the effects of cutting parameters on burr formation and minimization in ultra-precision grooving of amorphous alloy

Kobayashi, Ryuichi1; Xu, Shaolin2; Shimada, Keita1; Mizutani, Masayoshi1; Kuriyagawa, Tsunemoto3

2017-07

10.1016/j.precisioneng.2017.01.018

PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY   影响因子和分区

0141-6359

1873-2372

Amorphous nickel phosphorus (Ni-P) alloy is a suitable mold material for fabricating micropatterns on optical elements for enhancing their performances. Ultra-precision cutting is preferred to be used to machine the mold material for high precision in a large workpiece. However, burrs and chippings always form and are detrimental especially when fabricating micropatterns. The formation mechanisms of burrs and chippings have not yet been revealed precisely in the cutting processes of amorphous alloys, because their cutting behavior is more complex and less discussed in existing researches than that of crystalline metals. In the present study, the burr formation process of amorphous Ni-P is defined and a three-dimensional cutting model using energy method is proposed to predict and minimize burrs and chippings. Microgrooving experiments were conducted with different undeformed chip geometries using three types of cutting tools to observe burr formation processes. Large burrs and chippings were formed when cutting with a tapered square tool and a tilted triangle tool. These large burrs and chippings were found to be induced by large slippages that are unique to amorphous alloys. It was revealed that burrs and chippings appear when the angle between the chip flow direction and the groove edge is less than a critical value. Energy method was used to predict the chip flow directions and the calculated results agree with the experimental ones, which proved that the energy method is valid for designing an appropriate undeformed chip geometry to reduce burrs and chippings in ultra-precision grooving. (C) 2017 Elsevier Inc. All rights reserved.

Burrs and chipping Ultra-precision cutting Amorphous alloy Cutting parameters Energy method

SCI ; EI

英语

其他

Engineering ; Science & Technology - Other Topics ; Instruments & Instrumentation

Engineering, Multidisciplinary ; Engineering, Manufacturing ; Nanoscience & Nanotechnology ; Instruments & Instrumentation

WOS:000402444000013

ELSEVIER SCIENCE INC

20170603333025

Amorphous alloys ; Molds ; Nickel alloys ; Turning

Metallurgy and Metallography:531 ; Nickel Alloys:548.2 ; Machine Tool Accessories:603.2 ; Machining Operations:604.2

ENGINEERING

Web of Science

1.Tohoku Univ, Grad Sch Engn, Dept Mech Syst Engn, Aoba Ku, 6-6-01 Aramaki Aza Aoba, Sendai, Miyagi 9808579, Japan
2.South Univ Sci & Technol, Grad Sch Engn, Dept Mech & Energy Engn, 1088 Xueyuan Blvd, Shenzhen, Guangdong, Peoples R China
3.Tohoku Univ, Grad Sch Biomed Engn, Dept Biomed Engn, Aoba Ku, 6-6-01 Aramaki Aza Aoba, Sendai, Miyagi 9808579, Japan

Kobayashi, Ryuichi,Xu, Shaolin,Shimada, Keita,et al. Defining the effects of cutting parameters on burr formation and minimization in ultra-precision grooving of amorphous alloy[J]. PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY,2017,49:115-121.

Kobayashi, Ryuichi,Xu, Shaolin,Shimada, Keita,Mizutani, Masayoshi,&Kuriyagawa, Tsunemoto.(2017).Defining the effects of cutting parameters on burr formation and minimization in ultra-precision grooving of amorphous alloy.PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY,49,115-121.

Kobayashi, Ryuichi,et al."Defining the effects of cutting parameters on burr formation and minimization in ultra-precision grooving of amorphous alloy".PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY 49(2017):115-121.