Research On Micro Milling-grinding Process Surface Quality Control Methods

Miniaturization product plays a very important role in the future technological development of a broad spectrum of products owing to various advantages:small quality and size, low energy consumption, few resources consumption, beautiful, easy to use. Micro-cutting is the forward position in the field of advanced manufacturing, it is very important to the precious spares manufacturing in the fields of high-tech fields. Micro-cutting will be used to manufacture any shapes of3D spares of many kinds of materials; it will have a vast prospect.In recent years, micro cutting especially micro-milling have develop rapidly in related research about micro mechanical processing technology, but the surface quality of the micro cutting has not very ideal. Given the good quality of surface grinding, it adopts a new type of machining, Micro milling-grinding process. It not only overcomes the defects of larger surface roughness in micro-milling process, but also overcomes the insufficient of lower material removal rate in micro-grinding process.This thesis is an attempted and exploratory research concerning micro milling-grinding process, and it focuses on micro milling-grinding mechanism, factors affecting the machined surface quality and the practical process, the comparison to the micro-milling. The micro milling-grinding process is researched in the following aspects:First the chip formation mechanism about micro-cutting and the basic principle about micro milling-grinding process and the surface generated have been studied. Using the finite element simulation represent the machining process, and based on the characteristics of two kinds of different materials studied the stress field of different processing parameters concluding cutting speed and cutting depth, researched the micro-machining process and mechanism, the minimum thickness of cutting and restore elasticity effect, the influence of the processing surface residual stress on the surface quality.The micro milling-grinding machining system and the manufacturing processes of micro milling-grinding cutters are the first aspect of the research of micro-grinding process. This thesis used electroplating micro-powder to make micro milling-grinding cutter. In the experiments, the micro-milling orthogonal experiment and micro milling-grinding of single factor experiment have been operated, discussed influence law of the processing parameters and the size parameters of micro milling-grinding cutter to the surface quality.Then the micro milling-grinding surface quality was studied. Based on the experimental conditions associated in this experiment, surface roughness of workpiece materials is the main index, to study micro-scale factors influencing the quality of machined surface. Due to the micro milling-grinding process compound micro-milling and micro-grinding processing method, these two kinds of processing methods of various process parameters on the surface quality of the processing tendency should be discussed, and due to combined impact generated by the comprehensive influence and micro milling-grinding process cutters of properties itself making processing unachieved ideal condition, so in the actual machining process, the influence factors of surface roughness of workpiece will show some different trends.Finally, conclusions are drawn and some problems in experiment are illustrated. Some recommendations for future are provided.