Cutting edge preparation of micro end mills by PVD-etching technology
Micromilling tools face significant challenges in achieving cutting edge preparation by mechanical processes due to their small size. To address these limitations, a new approach for cutting edge preparation of micro end mills by physical vapor deposition (PVD) etching technology is presented. By ad...
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Published in | Production engineering (Berlin, Germany) Vol. 18; no. 3-4; pp. 459 - 473 |
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Main Authors | , , , , , |
Format | Journal Article |
Language | English |
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Berlin/Heidelberg
Springer Berlin Heidelberg
01.06.2024
Springer Nature B.V |
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Abstract | Micromilling tools face significant challenges in achieving cutting edge preparation by mechanical processes due to their small size. To address these limitations, a new approach for cutting edge preparation of micro end mills by physical vapor deposition (PVD) etching technology is presented. By adapting the etching strategy, which is conventionally used as pre-treatment process for PVD technology to clean and condition the surface of cemented carbide substrate, cutting edges of micromilling tools were successfully modified. The high-energy process variation by Advanced Arc-Enhanced Glow Discharge (AEGD) offers the possibility of achieving high material removal rates on the tool surfaces and thereby altering the cutting edge geometry. Fundamental investigations on material removal as well as on the effects on surface topography, sub-surface properties, and coating adhesion of a subsequently applied PVD coating are performed. To influence the topography and the cutting edge geometry, the preparation time
t
p
and bias voltage
U
B
were selected. Subsequently, the machining performance of the modified tools is evaluated in a micromilling process of the hardened powder-metallurgical high-speed steel AISI M3:2 with a hardness of 62 ± 1 HRC. For this purpose, micro end mills of cemented carbide with a diameter of
D
= 1 mm were conditioned, achieving asymmetric geometric properties of cutting edges with varying average cutting edges rounding of
S
¯
= 5.8 … 14.8 µm and a form-factor of
K
= 2.0 … 2.7. Based on the application tests a positive influence on the process forces was found. Thus, an efficient approach to cutting edge preparation can be identified by specifically designing ion etching in the PVD coating process. |
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AbstractList | Micromilling tools face significant challenges in achieving cutting edge preparation by mechanical processes due to their small size. To address these limitations, a new approach for cutting edge preparation of micro end mills by physical vapor deposition (PVD) etching technology is presented. By adapting the etching strategy, which is conventionally used as pre-treatment process for PVD technology to clean and condition the surface of cemented carbide substrate, cutting edges of micromilling tools were successfully modified. The high-energy process variation by Advanced Arc-Enhanced Glow Discharge (AEGD) offers the possibility of achieving high material removal rates on the tool surfaces and thereby altering the cutting edge geometry. Fundamental investigations on material removal as well as on the effects on surface topography, sub-surface properties, and coating adhesion of a subsequently applied PVD coating are performed. To influence the topography and the cutting edge geometry, the preparation time
t
p
and bias voltage
U
B
were selected. Subsequently, the machining performance of the modified tools is evaluated in a micromilling process of the hardened powder-metallurgical high-speed steel AISI M3:2 with a hardness of 62 ± 1 HRC. For this purpose, micro end mills of cemented carbide with a diameter of
D
= 1 mm were conditioned, achieving asymmetric geometric properties of cutting edges with varying average cutting edges rounding of
S
¯
= 5.8 … 14.8 µm and a form-factor of
K
= 2.0 … 2.7. Based on the application tests a positive influence on the process forces was found. Thus, an efficient approach to cutting edge preparation can be identified by specifically designing ion etching in the PVD coating process. Abstract Micromilling tools face significant challenges in achieving cutting edge preparation by mechanical processes due to their small size. To address these limitations, a new approach for cutting edge preparation of micro end mills by physical vapor deposition (PVD) etching technology is presented. By adapting the etching strategy, which is conventionally used as pre-treatment process for PVD technology to clean and condition the surface of cemented carbide substrate, cutting edges of micromilling tools were successfully modified. The high-energy process variation by Advanced Arc-Enhanced Glow Discharge (AEGD) offers the possibility of achieving high material removal rates on the tool surfaces and thereby altering the cutting edge geometry. Fundamental investigations on material removal as well as on the effects on surface topography, sub-surface properties, and coating adhesion of a subsequently applied PVD coating are performed. To influence the topography and the cutting edge geometry, the preparation time t p and bias voltage U B were selected. Subsequently, the machining performance of the modified tools is evaluated in a micromilling process of the hardened powder-metallurgical high-speed steel AISI M3:2 with a hardness of 62 ± 1 HRC. For this purpose, micro end mills of cemented carbide with a diameter of D = 1 mm were conditioned, achieving asymmetric geometric properties of cutting edges with varying average cutting edges rounding of $${\overline S}$$ S ¯ = 5.8 … 14.8 µm and a form-factor of K = 2.0 … 2.7. Based on the application tests a positive influence on the process forces was found. Thus, an efficient approach to cutting edge preparation can be identified by specifically designing ion etching in the PVD coating process. Micromilling tools face significant challenges in achieving cutting edge preparation by mechanical processes due to their small size. To address these limitations, a new approach for cutting edge preparation of micro end mills by physical vapor deposition (PVD) etching technology is presented. By adapting the etching strategy, which is conventionally used as pre-treatment process for PVD technology to clean and condition the surface of cemented carbide substrate, cutting edges of micromilling tools were successfully modified. The high-energy process variation by Advanced Arc-Enhanced Glow Discharge (AEGD) offers the possibility of achieving high material removal rates on the tool surfaces and thereby altering the cutting edge geometry. Fundamental investigations on material removal as well as on the effects on surface topography, sub-surface properties, and coating adhesion of a subsequently applied PVD coating are performed. To influence the topography and the cutting edge geometry, the preparation time tp and bias voltage UB were selected. Subsequently, the machining performance of the modified tools is evaluated in a micromilling process of the hardened powder-metallurgical high-speed steel AISI M3:2 with a hardness of 62 ± 1 HRC. For this purpose, micro end mills of cemented carbide with a diameter of D = 1 mm were conditioned, achieving asymmetric geometric properties of cutting edges with varying average cutting edges rounding of S¯= 5.8 … 14.8 µm and a form-factor of K = 2.0 … 2.7. Based on the application tests a positive influence on the process forces was found. Thus, an efficient approach to cutting edge preparation can be identified by specifically designing ion etching in the PVD coating process. |
Author | Jäckel, Christoph Paul Tillmann, Wolfgang Stangier, Dominic Lopes Dias, Nelson Filipe Meijer, Alexander Leonard Biermann, Dirk |
Author_xml | – sequence: 1 givenname: Christoph Paul orcidid: 0009-0003-4457-3396 surname: Jäckel fullname: Jäckel, Christoph Paul email: christoph.jaeckel@tu-dortmund.de organization: Institute of Machining Technology, TU Dortmund University – sequence: 2 givenname: Alexander Leonard orcidid: 0000-0002-5255-4000 surname: Meijer fullname: Meijer, Alexander Leonard organization: Institute of Machining Technology, TU Dortmund University – sequence: 3 givenname: Dominic orcidid: 0000-0003-3271-4705 surname: Stangier fullname: Stangier, Dominic organization: Institute of Materials Engineering, TU Dortmund University, Oerlikon Balzers Coating Germany GmbH – sequence: 4 givenname: Nelson Filipe orcidid: 0000-0002-0541-4697 surname: Lopes Dias fullname: Lopes Dias, Nelson Filipe organization: Institute of Materials Engineering, TU Dortmund University – sequence: 5 givenname: Wolfgang orcidid: 0000-0001-7270-4187 surname: Tillmann fullname: Tillmann, Wolfgang organization: Institute of Materials Engineering, TU Dortmund University – sequence: 6 givenname: Dirk orcidid: 0000-0001-8215-0093 surname: Biermann fullname: Biermann, Dirk organization: Institute of Machining Technology, TU Dortmund University |
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Cites_doi | 10.1016/j.procir.2012.04.033 10.1016/0257-8972(95)02554-5 10.1007/978-3-642-33257-9 10.1016/j.ijrmhm.2017.08.015 10.1016/j.cirp.2010.03.056 10.1016/j.cirp.2014.05.009 10.1007/BF00324008 10.1016/S0924-0136(03)00846-X 10.1016/j.cirp.2022.04.065 10.3390/coatings11111387 10.1007/978-1-4471-0647-0_17 10.1007/s11740-017-0787-7 10.1016/j.ijmachtools.2004.12.003 10.3390/ma14237324 10.1016/j.cirpj.2012.03.004 10.1016/0257-8972(93)90074-X 10.1016/j.surfcoat.2005.11.082 10.1016/j.cirp.2010.03.065 10.3390/jmmp6020037 10.1016/j.cirp.2012.05.006 10.1016/j.cirp.2011.03.098 10.1016/j.procir.2016.04.004 10.1007/s40430-016-0545-3 10.1016/j.tsf.2009.10.145 10.1016/j.procir.2014.03.083 10.1016/S0257-8972(99)00552-6 10.1002/mawe.19960270907 |
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Keywords | Physical vapor deposition Cutting edge preparation Advanced Arc-Enhanced Glow Discharge Asymmetrical cutting edge geometry Micromilling |
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Snippet | Micromilling tools face significant challenges in achieving cutting edge preparation by mechanical processes due to their small size. To address these... Abstract Micromilling tools face significant challenges in achieving cutting edge preparation by mechanical processes due to their small size. To address these... |
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StartPage | 459 |
SubjectTerms | Carbide tools Cemented carbides Coating Electric arcs Engineering Etching Glow discharges High speed tool steels Industrial and Production Engineering Ion etching Machining Metallurgical analysis Mills Physical vapor deposition Processes Production Substrates Surface properties Topography |
Title | Cutting edge preparation of micro end mills by PVD-etching technology |
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