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Open AccessArticle

Research on Parameter Optimization of Micro-Milling Al7075 Based on Edge-Size-Effect

College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave 3688, Shenzhen 518060, Guangdong, China
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Micromachines 2020, 11(2), 197; https://doi.org/10.3390/mi11020197
Received: 1 January 2020 / Revised: 31 January 2020 / Accepted: 9 February 2020 / Published: 14 February 2020
(This article belongs to the Section D:Materials and Processing)
In the process of micro-milling, the appearance of the edge-size-effect of micro-milling tools cannot be ignored when the cutting parameters are smaller than the cutting edge arc radius (r0) of the micro-milling tool or close to it, and it could easily lead to low cutting efficiency and poor surface quality of the micro-slot. Through micro-milling experiments on Al7075-T6 materials, the change of milling force in the plough zone and shear zone during micro-milling was studied, and the minimum cutting thickness (hmin) range was determined to be 0.2r0–0.4r0 based on r0 of the micro-milling tool. Subsequently, the effect of fz/r0 (fz denotes feed rate per tooth) on the top burr formation of the micro-slot, the surface roughness (Ra) of the micro-slot bottom, and the milling force was studied, and a size-effect band of micro milling was established to determine the strong size-effect zone, transition size-effect zone, and the weak size-effect zone. Finally, two different fz/r0 in the strong size-effect zone and the weak size-effect zone are compared, which proves that the main purpose of the cutting parameters optimization of micro-milling is to avoid cutting parameters locating in the strong edge-size-effect zone. The above conclusions provide a theoretical basis for the selection of micro-milling cutting parameters, and an important reference in improving the surface quality of micro-milling.
Keywords: micro-milling; edge-size-effect; burr; surface quality; cutting parameter optimization micro-milling; edge-size-effect; burr; surface quality; cutting parameter optimization
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Chen, Y.; Wang, T.; Zhang, G. Research on Parameter Optimization of Micro-Milling Al7075 Based on Edge-Size-Effect. Micromachines 2020, 11, 197.

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