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research-article

AN IN-PROCESS INTERVENTION TO MITIGATE THE EFFECT OF BUILT-UP EDGES IN MICRO-MILLING

[+] Author and Article Information
Robert Altman

Graduate Research Assistant, Department of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, Troy, NY 12180
altmar2@rpi.edu

James F. Nowak

Graduate Research Assistant, Department of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, Troy, NY 12180
nowakj2@rpi.edu

Johnson Samuel

Associate Professor, Department of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, Troy, NY 12180
samuej2@rpi.edu

1Corresponding author.

ASME doi:10.1115/1.4037574 History: Received December 28, 2016; Revised August 04, 2017

Abstract

This paper is focused on developing an in-process intervention technique that mitigates the effect of built-up edges (BUEs) during micro-milling of aluminum. The technique relies on the intermittent removal of the BUEs formed during the machining process. This is achieved using a three-stage intervention that consists first of the mechanical removal of meso-scale BUEs, followed by an abrasive slurry treatment to remove the micro-scale BUEs. Finally, the tool is cleaned using a non-woven fibrous mat to remove the slurry debris. An on-machine implementation of this intervention technique is demonstrated, followed by a study of its influence on key micro-machining outcomes such as tool wear, cutting forces, part geometry, and burr formation. In general, all relevant machining measures are found to improve significantly with the intervention. The key attributes of this intervention that makes it viable for micro-machining processes include: (i) An experimental setup that can be implemented within the working volume of the micro-scale machine tool; (ii) No removal of the tool from the spindle, which ensures that the intervention does not change critical process parameters such as tool runout and offset values; and (iii) Implementation in the form of canned G-code subroutines dispersed within the regular micro-machining operation.

Copyright (c) 2017 by ASME
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