Accepted Manuscripts

Ahmed Abdelrahman Elkaseer, Jon Lambarri, Jon Ander Sarasua and Itxaso Cascon
J. Micro Nano-Manuf   doi: 10.1115/1.4036933
This paper reports the development of an original design of chip breaker in a metal-matrix polycrystalline diamond (MMPCD) insert brazed into a milling tool. The research entailed finite element (FE) design, laser simulation, laser fabrication and machining tests. FE analysis was performed to evaluate the effectiveness of different designs of chip breaker, under specified conditions when milling aluminium alloy (Al A356). Then, the ablation performance of a MMPCD workpiece was characterised by ablating single trenches under different conditions. The profiles of the generated trenches were analysed and fed into a simulation tool to examine the resultant thickness of ablated layers for different process conditions, and to predict the obtainable shape when ablating multi-layers. Next, the geometry of the designated chip breaker was sliced into a number of layers to be ablated sequentially. Different ablation scenarios were experimentally investigated to identify the optimum processing conditions. The results showed that a ns-laser utilised in a controllable manner successfully produced the necessary three-dimenisonal feature of an intricate chip breaker with high surface quality (Ra in the sub-micron range), tight dimensional accuracy (maximum dimensional error was less than 4%) and in an acceptable processing time (?51 seconds). Finally, two different inserts brazed in milling tools, with and without the chip breaker, were tested in real milling trials. Superior performance of the insert with chip breaker was demonstrated by the curled chips formed and the significant reduction of obtained surface roughness compared to the surface produced by the insert without chip breaker.
TOPICS: Metals, Lasers, Machining, Ablation (Vaporization technology), Design, Milling, Simulation, Finite element analysis, Diamonds, Errors, Geometry, Aluminum alloys, Manufacturing, Surface roughness, Shapes, Surface quality

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