Research On Tool Wear Mechanisms And Factors Affectting Burr Formation For Micro Milling

With the increasing development of modern science and technology, microminiaturization has been more and more widely used in the fields of biomedicine, aviation, national defense and high-tech electronics, etc. It has become frontal research on modern science and technology. With the characteristics of high efficiency, high flexibility and capability of machining complicated three-dimensional parts in a wide range of materials, micro-machining Technology has become a very important means against the limitation in MEMS and become the most active and hot research subject. However, the machining performance of micro tool is low, behaved as quick tool wear, frequent tool fracture, also the machining quality is not high, there is always burr generated on the edge and in the groove. In order to solve the problems raised above, the mechanism of micro tool wear and formation of burr is systematically studied in this paper, and the specific contents contain the following three aspects:Firstly, using numerical simulation, the finite element model of micro tool wear in micro-milling process is established to investigate the mechanical performance of micro-milling tool. The changing form of micro tool wear is also studied and a new method of measuring micro tool wear has been put forward, at last the variation regularities of the effect of cutting parameters on tool wear has been summarized.Secondly, based on the self-designed 3 axis micro milling machine, the wear form of micro-milling tool is studied by lots of experiments using scanning electronic microscope, energy spectrometer and focusing microscope, having got the result that tool wear at the tool nose is serious. Then the wear mechanism is analyzed, and the wear curve is also plotted. Comparing the results of experimental and numerical simulation, the emulational model and results are verified.Finally, the influence of cutting parameters and tool wear on burr formation are studied through the experiment of machining micro-flute. The main position to form burr is the two side edges on top of micro-flute and the main factors to form burr is cutting depth and tool edge radius, and the optimized cutting parameters and conditions for machining micro-flute are obtained.