The effect of different cutting parameters on cutting force, tool wear and burr formation in micro milling WCu composite material fabricated via powder metallurgy

Abstract

In this study, the wears that occurred on the cutting tool edges as a result of being subjected to micro-milling process of W-30%wtCu composite material produced by sintering at 1000 0C were investigated. A series of micro-milling tests were carried out at a constant cutting depth to determine the effect of different feed rates on tool wear. End-mill tools with a diameter of 0.5 mm and two flutes were used in the micro-milling process. Surface images of composite material after sintering and worn surfaces' images of cutting tools after micro-milling process were obtained by utilizing scanning electron microscopy (SEM). Tool wear was followed from digital screen by measuring cutting forces with dynamometer. Suitable cutting speed and feed rate for micro-milling of W-30%wtCu composite material were established by observing tool wear. The results showed that minimum tool wear had taken place at 35 mm/min feed rate and maximum cutting speed. Amount of burr formation was always increased from 1. slot towards 6. slot in all micro milling processes.