Effect of workpiece material on surface roughness in ultraprecision raster milling

S. J. Wang, Suet To, Chi Fai Cheung

Research output: Journal article publicationJournal articleAcademic researchpeer-review

15 Citations (Scopus)

Abstract

This article presents theoretical and experimental investigations into the effect of the workpiece material on surface roughness in ultraprecision raster milling (UPRM). The influence of material elastic recovery on chip thickness and surface generation in UPRM is studied. A holistic surface roughness prediction model is developed by considering the influences of cutting parameters, tool geometry and the material elastic recovery on surface generation. The experimental results show that the proposed surface roughness prediction model makes a more precise prediction by adding the elastic recovery rate as a material factor, and the presence of elastic recovery improves the surface finishing of the raster milled surface. The material effect on surface roughness decreases with the increasing of feed rate. The precipitates in the machining of aluminum alloy 6061 result in the generation of imperfection on the raster milled surface. The machining of aluminum bronze has the greatest influence on surface roughness among the three materials being cut, which is due to its high elastic recovery rate and hardness.
Original languageEnglish
Pages (from-to)1022-1028
Number of pages7
JournalMaterials and Manufacturing Processes
Volume27
Issue number10
DOIs
Publication statusPublished - 1 Oct 2012

Keywords

  • Elastic
  • Milling
  • Precipitation
  • Recovery
  • Roughness
  • Ultraprecision

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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