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Direct machining of micro patterns on nickel alloy and mold steel by vibration assisted cutting

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Abstract

Feasibility of direct machining of micro patterns for micro molds by 2-dimensional vibration assisted cutting or elliptical vibration cutting was investigated and its machinability was compared with the conventional cutting method. Micro patterns of successive V-grooves and micro pyramids were machined on workpieces of a pure nickel, nickel alloy and mold steels with single crystal diamond, cubic boron nitride and poly crystal diamond tools which move along a circular path with a diameter less than 2 μm at an excitation frequency of 18 kHz. It was observed that the utility of EVC, that is a decrease of cutting resistance and an improved machining quality, was retained regardless of materials of workpieces and tools, and the improvement compared to CCM was far clearer when machined with a worn cutting tool. The risk of catastrophic or fatigue failure of tool was, however, increased by the impulsive forces resulting from periodic contact making and breaking between the tool and workpiece of high strength and hardness.

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Abbreviations

CCM :

Conventional cutting method

EVC :

Elliptical vibration cutting

V x (t),V x (t):

Voltages applied to the horizontal (PZT x ) and vertical (PZT y ) piezoelectric actuators

ϕ :

Phase difference between two PZTs

u(t),v(t):

Displacements generated by PZT x (u(t)) and PZT y (v(t)) in the cutting(x) and thrust(y) direction

v f :

Feed speed [mm/s]

d :

Depth of cut [µm]

f :

Excitation frequency of elliptical vibration of cutting tool [kHz]

A c (A t ):

Amplitude of elliptical locus of cutting tool in the cutting (thrust) direction [µm]

S v :

Spacing between adjacent grooves [µm]

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Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Catholic University of Daegu, Hayang-eup, Gyeongsan-si, Gyeongbuk, South Korea, 712-702

    Gi Dae Kim

  2. Department of Mechanical Systems Engineering, Hansung University, Samsun-dong 389, Sungbuk-gu, Seoul, South Korea, 136-792

    Byoung Gook Loh

Authors
  1. Gi Dae Kim
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  2. Byoung Gook Loh
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Correspondence to Gi Dae Kim.

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Kim, G.D., Loh, B.G. Direct machining of micro patterns on nickel alloy and mold steel by vibration assisted cutting. Int. J. Precis. Eng. Manuf. 12, 583–588 (2011). https://doi.org/10.1007/s12541-011-0075-y

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  • DOI: https://doi.org/10.1007/s12541-011-0075-y

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