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Title: An investigation on surface finishing in ultra-precision raster milling of aluminum alloy 6061
Authors: Wang, SJ
To, S 
Chen, X
Chen, XD
Keywords: Aluminum alloy 6061
Surface topography
Ultra-precision milling
Issue Date: 2015
Publisher: SAGE Publications
Source: Proceedings of the Institution of Mechanical Engineers. Part B, Journal of engineering manufacture, 2015, v. 229, no. 8, p. 1289-1301 How to cite?
Journal: Proceedings of the Institution of Mechanical Engineers. Part B, Journal of engineering manufacture 
Abstract: The technology of ultra-precision machining with single crystal diamond tool produces advanced components with a higher dimensional accuracy and a better surface quality. This article develops a three-dimensional surface topography simulation model for ultra-precision raster milling process by considering the effect of cutting parameters, tool geometry and tool interference as well as the tool-workpiece relative movement on surface generation. Based on the developed surface topography simulation model, a prediction model for the surface roughness in ultra-precision raster milling is built. The effects of depth of cut and surface topography on the cutting-induced heat generation in ultra-precision milling of aluminum alloy 6061 are investigated. Experiment is conducted to verify the developed surface topography simulation model by raster milling of aluminum alloy 6061 under different feed rates and depths of cut. The experimental results show that the surface topography simulation model can properly simulate the surface profile in the raster milling process and the predicted surface roughness agrees well with the measured results of the machined workpiece. Heat generation in horizontal cutting is less than that in vertical cutting and a larger depth of cut generates more heat on the machined workpiece. The cutting-induced heat generates precipitate on the machined aluminum alloy 6061 which results in a worse surface finish in ultra-precision raster milling.
ISSN: 0954-4054
EISSN: 2041-2975
DOI: 10.1177/0954405414535588
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