Sun Yao, Jin Liya, Gong Yadong, Qi Yang, Zhang Huan, Su Zhipeng, Sun Kai
School of Mechanical Engineering and Automation, Northeastern University, Shenyang 110819, China.
Siasun Robot and Automation Co., Ltd., Shenyang 110169, China.
Materials (Basel). 2020 Oct 19;13(20):4664. doi: 10.3390/ma13204664.
Aluminum alloy material is widely used in the electronics, weapons, aviation and aerospace industries, due to its medium strength, good corrosion resistance, good toughness and excellent oxidation properties. With the trend of product miniaturization, micro cutting has become the mainstream technique for fabricating micro parts and components, so it is very meaningful and vital to work on removing the cutting fluid from the micro cutting process and make it totally sustainable and eco-friendly. In this work, an attempt has been made to fabricate micro textures onto the rear surface of helical micro end mills with diameters of less than 1 mm. Micro textures in the form of grooves were fabricated using a noncontact low speed wire electrical discharge turning technique. Dry micro cutting experiments were carried out on an aluminum alloy material using helical micro end mills with micro textures and the dry micro cutting surface quality and tool wear have been investigated. The influence of dry micro cutting parameters on the surface roughness parameters were also investigated. Experimental results showed that the and can be reduced to be about 1.56 μm and 2.08 μm, respectively. Contrasting results indicate that the implantation of micro textures does not deteriorate the dry micro cutting surface but improves the machined surface consistency of an aluminum alloy workpiece. The tool wear on helical micro end mills with micro textures involved in the dry micro cutting process of Al 6061 mainly include rear frictional wear, oxidation wear and diffusion wear.
铝合金材料因其中等强度、良好的耐腐蚀性、良好的韧性和优异的氧化性能，在电子、武器、航空航天等行业得到广泛应用。随着产品小型化的趋势，微切削已成为制造微型零部件的主流技术，因此致力于从微切削过程中去除切削液并使其完全可持续和环保具有非常重要的意义。在这项工作中，尝试在直径小于1mm的螺旋微端铣刀后刀面上制造微织构。采用非接触式低速电火花车削技术制造出沟槽形式的微织构。使用带有微织构的螺旋微端铣刀对铝合金材料进行干式微切削实验，并研究了干式微切削表面质量和刀具磨损情况。还研究了干式微切削参数对表面粗糙度参数的影响。实验结果表明， 和 可分别降低至约1.56μm和2.08μm。对比结果表明，微织构的植入不会使干式微切削表面恶化，反而提高了铝合金工件的加工表面一致性。参与6061铝合金干式微切削过程的带有微织构的螺旋微端铣刀的刀具磨损主要包括后刀面摩擦磨损、氧化磨损和扩散磨损。
