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<p>The minimum uncut chip thickness plays a critical role in micro milling, determining whether chip formation occurs or if the process is dominated by rubbing and elastic–plastic deformation. Researchers have tried to determine the minimum chip thickness for each pair of tool-material, aiming to machine above this range; however, the literature has largely focused on conservative feed per tooth (fz) values. Addressing this gap, this work evaluated the use of high feed values on the micro milling of Inconel 718 using two-flute, TiAlN-coated carbide micro tools with a 400-µm diameter. The fz was varied from 0.1 to 25.0 µm/tooth. The surface quality was analyzed through roughness parameters, burr height, SEM imaging, and cutting force measurements. The results showed that Ra, Rq, Rt, and Rp increased with the fz, although absolute roughness values remained low, with the highest Ra being 0.32 µm. The Rsk was positive for all the parameters with exception of the lowest fz, and kurtosis (Rku) exceeded 3 for all feed rates except fz = 5.0 µm/tooth. Burr height decreased significantly with increasing fz, with the highest value of fz resulting in a burr with 1.4 μm, a 98.3% reduction when compared to the smallest fz. Specific cutting forces also decreased markedly, showing a 99% reduction across the tested range. The considered extremely high value of 25.0 µm/tooth proved to be the most favorable, producing qualitatively good surfaces with minimal burr formation and lower specific energy, indicating improved chip formation. This condition also enhances productivity and reduces the need for post-processing.</p>

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On the use of extremely high feed per tooth as an alternative to reduce size effects during the micro milling of critically low machinability alloy Inconel 718

  • 期刊论文

  • 发表日期：

    2025年7月24日

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  • Déborah de Oliveira,
  • Milla Caroline Gomes,
  • Maksym Ziberov,
  • Marcello Bulhões Montagnana,
  • Mark James Jackson,
  • Marcio Bacci da Silva

摘要

The minimum uncut chip thickness plays a critical role in micro milling, determining whether chip formation occurs or if the process is dominated by rubbing and elastic–plastic deformation. Researchers have tried to determine the minimum chip thickness for each pair of tool-material, aiming to machine above this range; however, the literature has largely focused on conservative feed per tooth (fz) values. Addressing this gap, this work evaluated the use of high feed values on the micro milling of Inconel 718 using two-flute, TiAlN-coated carbide micro tools with a 400-µm diameter. The fz was varied from 0.1 to 25.0 µm/tooth. The surface quality was analyzed through roughness parameters, burr height, SEM imaging, and cutting force measurements. The results showed that Ra, Rq, Rt, and Rp increased with the fz, although absolute roughness values remained low, with the highest Ra being 0.32 µm. The Rsk was positive for all the parameters with exception of the lowest fz, and kurtosis (Rku) exceeded 3 for all feed rates except fz = 5.0 µm/tooth. Burr height decreased significantly with increasing fz, with the highest value of fz resulting in a burr with 1.4 μm, a 98.3% reduction when compared to the smallest fz. Specific cutting forces also decreased markedly, showing a 99% reduction across the tested range. The considered extremely high value of 25.0 µm/tooth proved to be the most favorable, producing qualitatively good surfaces with minimal burr formation and lower specific energy, indicating improved chip formation. This condition also enhances productivity and reduces the need for post-processing.