Abstract
This paper presents a method for material removal in micron level with high accuracy and surface finish using a CNC machine. In this work, commercially available pure aluminum 19,000 rods are micro-machined with TNMG 1,60,404 (TiN) Inserts, as cutting tool. The Al19000 rod is electroplated with Nickel for plating thickness of 21.5 μm. While machining the actual material removed is the difference between the depth of cut given and the electroplating thickness. Since the electroplating thickness is less than 100 μm and minimum possible depth of cut given is 100 μm, the actual work-piece metal removal is in the order of microns. Thus micromachining is achieved using CNC turning machine. The experiments were conducted with various combinations of cutting speed, feed, and depth of cut. Performance responses such as Surface Roughness (SR) and Metal Removal (MR) for different conditions were measured and reported. Optimum machining conditions were identified. The machined surface was viewed using Scanning Electron Microscope (SEM) and SEM image were correlated with micro scratches, worn surface, dirty layer formed for different cutting condition.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Taguchi N (1993) Current status in, and future trends of ultraprecision machining and ultrafine materials processing. Ann CIRP 32(2):573–582
Madou M (1997) Fundamentals of micro fabrication. CRC Press, Ohio
Corbett J, McKeon PA, Peggs GN, Whatmore R (2000) Nanotechnology, international developments and emerging products. Ann CIRP 49(3):473–478
McGeough JA (2002) Micromachining of engineering materials. Dekker, NY
Gowri S, Ranjith Kumar P, Vijayaraj R, Balan ASS (2007) Micromachining: technology for the future. Int J Mater Struct Integrity 1(2/3):161–179
Ranjith Kumar P, Balan ASS, Gowri S (2010) Monitoring and prediction of tool wear in micro turning of copper. Int J Precision Technol, 1: 3/4
Rahman MA, Rahman M, Senthil Kumar A, Lim HS, Asad ABMA (2006) Development of micro pin fabrication process using tool based micromachining. Int J Adv Manuf Technol 27:939–944
Frazier AB, Allen MG (1997) Uses of electroplated aluminum for the development of microstructures and micromachining processes, J Micro Electromechanical Syst, 6: 2
Choudhury IA, EI-Baradie MA (1997) Surface roughness prediction in the turning of high-strength steel by factorial design of experiments. J Mater Process Technol 67(1–3):55–61
Pawade RS, Suhas S, Joshi (2011) Multi-objective optimization of surface roughness and cutting forces in high-speed turning of inconel 718 using Taguchi grey relational analysis (TGRA), Int J Adv Manuf Technol 56:47–62
Oezel T, Karpat Y (2005) Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks int. J Mach Tools Manuf 45(4–5):467–479
Bharathi Raja S, Baskar S (2011) Particle swarm optimization technique for determining optimal machining parameters of different work piece materials in turning operation’. Int J Adv Manuf Technol 54:445–463
Cakir MC, Gurarda A (1998) Optimization and graphical representation of machining conditions in multi-pass turning operations. Comput Integr Manuf Syst 11:157–170
Meng Q, Arsecularratne JA, Mathew P (2000) Calculation of optimum cutting conditions for turning operations using a machining theory. Int J Mach Tools Manuf 40:1709–1733
Singh D, Rao PV (2007) A surface roughness prediction model for hard turning process. Int J Adv Manuf Technol 32:1115–1124
Ross P (1988) Taguchi techniques for quality engineering-loss function, orthogonal experiments parameter and tolerance design. McGraw Hill, NY, pp 10–50
Taguchi G, Konishi S (1987) Taguchi methods, orthogonal arrays and linear graphs, tools for quality engineering. Am Supplier Inst, pp 35–38
Taguchi G (1993) Taguchi on robust technology development methods. ASME, New York, pp 1–40
Yang W, Tarng Y (1998) Design optimization of cutting parameters for turning operations based on the Taguchi method. J Mater Process Technol 84:122–129
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2012 Springer India
About this paper
Cite this paper
Rajkumar, D., Ranjithkumar, P., Sathiyanarayanan, C. (2012). Investigation of Micromachining on CNC. In: Sathiyamoorthy, S., Caroline, B., Jayanthi, J. (eds) Emerging Trends in Science, Engineering and Technology. Lecture Notes in Mechanical Engineering. Springer, India. https://doi.org/10.1007/978-81-322-1007-8_22
Download citation
DOI: https://doi.org/10.1007/978-81-322-1007-8_22
Published:
Publisher Name: Springer, India
Print ISBN: 978-81-322-1006-1
Online ISBN: 978-81-322-1007-8
eBook Packages: EngineeringEngineering (R0)