Development and analysis of all-ceramic micro end mills with diameters ≤ 50 µm

直径≤50 µm全陶瓷微型立铣刀的研制与分析

• 批准号: 407558930
• 负责人: Professor Dr.-Ing. Jan C. Aurich
• 金额: --
• 依托单位: Lehrstuhl für Fertigungstechnik und Betriebsorganisation (FBK)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2018
• 资助国家: 德国
• 起止时间: 2017-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/407558930?language=en
• 关键词: Development; analysis; ceramic; micro; end

Micro milling offers significant advantages compared to other micro machining methods. These advantages are the high range of machinable materials, the achievable geometric complexity as well as the high surface quality. Today, end mills with diameters ≤ 50 µm are almost exclusively made of cemented carbide, due to its good material properties and machinability.However, the low tool diameters of the cemented carbide tools lead to a reduction of tool stability, while the specific cutting forces increase disproportionately. Furthermore, due to the increasing influence of the cutting edge radius, the so-called ploughing-effect occurs, which means that the workpiece material is pressed underneath the cutting edge and pushed through without being cut. In addition to a deterioration of the surface quality and increasing burr formation, the ploughing-effect leads to increased process forces and a strong wear of the filigree micro tool. Due to the microstructure and the grain size of the cemented carbides used, the minimum cutting edge radii of the tools is limited by the grain size of ultra-fine-grained carbides (0.2 µm).Caused by their microstructure, using ceramics as cutting material can further reduce the achievable cutting edge radii of the tools and thus the occurring process forces. In addition, ceramics have a higher hot hardness and wear resistance than cemented carbides, but are currently not applied for milling tools with tool diameters ≤ 50 μm.The overall goal of the research project is the first-time development and application of fully ceramic micro milling tools with diameters ≤ 50 μm. In analogy to macro cutting tools, the novel ceramic end mills are expected to reduce tool wear. In addition, improved surface quality of the workpieces, reduced burr formation and a higher tool life are expected. For this purpose, suitable cutting ceramics are selected and analogy tests for wear investigations are carried out. On this basis, the tool geometry of the fully ceramic end mills is developed by numerical and kinematic simulation. The micro end mills produced via grinding are used for milling tests. The results are compared with milling results of existing cemented carbide end mills produced in the proposer’s lab.

与其他微加工方法相比，微型铣削具有显着优势。这些优势是高度加工材料，可实现的几何复杂性以及高表面质量。如今，由于其良好的材料特性和加工，直径≤50µm的末端磨坊几乎完全由碳化物固定制成。但是，粘贴碳化物工具的低工具直径导致刀具稳定性的降低，而特定切割力则增加了不成比例的。此外，由于尖端半径的影响不断增长，所谓的盖子效应会发生，这意味着工作场所材料被压在尖端下方，并不被切割。除了对表面质量的定义和增加的毛毛形成外，底漆效应还导致工艺力增加和丝质微型微型工具的磨损。由于微观结构和所使用的胶结碳化物的晶粒尺寸，工具的最小尖端半径受到超细颗粒碳化物（0.2 µm）的晶粒尺寸的限制。由其微结构用作陶瓷作为切割材料来造成的，可以进一步降低工具和所发生的工具的可取的较前沿RADII的速度。此外，陶瓷具有比胶结碳化物更高的硬度硬度和耐磨性，但目前尚未用于铣削工具的工具直径≤50μmm。研究项目的总体目标是首次开发和应用全陶瓷微型铣削工具，其直径≤50μm。与宏切割工具相比，新型的陶瓷末端磨坊有望减少工具磨损。此外，预计工件的表面质量提高了，伯尔组的减少和更高的工具寿命。为此，选择了合适的切割陶瓷，并进行了类比测试，以进行磨损调查。在此基础上，完全陶瓷末端磨坊的工具几何形状是由数值和运动学模拟开发的。通过研磨生产的微端磨坊用于研磨测试。将结果与提案实验室生产的现有碳化物末端磨坊的铣削结果进行了比较。