Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method

Authors : Ahmet Hasçelik, Kubilay Aslantas

Pages : 134-146

Doi:10.55546/jmm.1200156

View : 26 | Download : 33

Publication Date : 2023-06-26

Article Type : Research Article

Abstract :Micro-thin-walled structures are frequently encountered in micro-pumps, micro-channel cooler plates, and micro-molds in the defense, aerospace and biomedical sectors. One of the micro-machining methods frequently used to obtain micro-thin-walled structures is micro-milling. The micro-milling method makes machining possible for micro-components with high accuracy and a good surface finish. However, there are many issues to consider when micro-milling thin-walled geometries. The fact that the wall deformation is directly related to the rate of progression necessitates knowing what effects the rate of progression cause on the wall deformation. Because the micro milling technique is generally used as the final cutting process in the creation of thin wall geometries in the industry. In this study, thin-walled structures were obtained by micro-milling the Al6061-T6 material. The influence of feed rate on wall deformation was investigated by applying different feed rates in micro milling experiments. Wall deformation measurements were performed using a motorized optical profilometer device. It has been observed that increasing feed value causes an enhance in cutting forces, it also causes an increase in the deformation of the micro-thin wall. The deformation distance between the end points of the micro-milled wall geometry using a feed rate of 1 µm/tooth is three times greater than the thin-wall geometry created using a feed rate of 0.2 µm/tooth. It has been determined that the deformation is much higher in the entrance and exit areas of the micro-thin wall. The wall deformation also decreases from the upper point to the lower points of the micro-thin wall. While the deviation distance in the measurement taken from the upper point of the wall geometry obtained by using the 1 µm/tooth feed rate, where the deformation is more, can reach 100 µm, the deviation at the lower point of the wall is negligible.
Keywords : İnce Duvar Yapıları, Mikro Frezeleme, Plastik Deformasyon, Kesme Parametreleri, Al6061-T6