Details
| Original language | English |
|---|---|
| Pages (from-to) | 3087-3102 |
| Number of pages | 16 |
| Journal | International Journal of Advanced Manufacturing Technology |
| Volume | 116 |
| Early online date | 16 Jul 2021 |
| Publication status | Published - Oct 2021 |
Abstract
The calibration of areal surface topography measuring instruments is of high relevance to estimate the measurement uncertainty and to guarantee the traceability of the measurement results. Calibration structures for optical measuring instruments must be sufficiently small to determine the limits of the instruments. Besides other methods, micro-milling is a suitable process for manufacturing areal material measures. For the manufacturing by micro-milling with ball end mills, the tool radius (effective cutter radius) is the corresponding limiting factor: if the tool radius is too large to penetrate the concave profile details without removing the surrounding material, deviations from the target geometry will occur. These deviations can be detected and excluded before experimental manufacturing with the aid of a kinematic simulation. In this study, a kinematic simulation model for the prediction of the dimensional accuracy of micro-milled areal material measures is developed and validated. Subsequently, a radius study is conducted to determine how the tool radius r of the tool influences the dimensional accuracy of an areal crossed sinusoidal (ACS) geometry according to ISO 25178-70 [1] with a defined amplitude d and period length p. The resulting theoretical surface texture parameters are evaluated and compared to the target values. It was shown that the surface texture parameters deviate from the nominal values depending on the effective cutter radius used. Based on the results of the study, it can be determined with which effective tool radius the measurands Sa and Sq of the material measures are best met. The ideal effective radius for the application considered is between 50 and 75 μm.
Keywords
- Kinematic simulation, material measures, Micro-milling
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Computer Science(all)
- Software
- Engineering(all)
- Mechanical Engineering
- Computer Science(all)
- Computer Science Applications
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: International Journal of Advanced Manufacturing Technology, Vol. 116, 10.2021, p. 3087-3102.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Analysis of dimensional accuracy for micro-milled areal material measures with kinematic simulation
AU - Klauer, Katja
AU - Eifler, Matthias
AU - Kirsch, Benjamin
AU - Böß, Volker
AU - Seewig, Jörg
AU - Aurich, Jan C.
N1 - Funding Information: Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) - project number 172116086 - SFB 926.
PY - 2021/10
Y1 - 2021/10
N2 - The calibration of areal surface topography measuring instruments is of high relevance to estimate the measurement uncertainty and to guarantee the traceability of the measurement results. Calibration structures for optical measuring instruments must be sufficiently small to determine the limits of the instruments. Besides other methods, micro-milling is a suitable process for manufacturing areal material measures. For the manufacturing by micro-milling with ball end mills, the tool radius (effective cutter radius) is the corresponding limiting factor: if the tool radius is too large to penetrate the concave profile details without removing the surrounding material, deviations from the target geometry will occur. These deviations can be detected and excluded before experimental manufacturing with the aid of a kinematic simulation. In this study, a kinematic simulation model for the prediction of the dimensional accuracy of micro-milled areal material measures is developed and validated. Subsequently, a radius study is conducted to determine how the tool radius r of the tool influences the dimensional accuracy of an areal crossed sinusoidal (ACS) geometry according to ISO 25178-70 [1] with a defined amplitude d and period length p. The resulting theoretical surface texture parameters are evaluated and compared to the target values. It was shown that the surface texture parameters deviate from the nominal values depending on the effective cutter radius used. Based on the results of the study, it can be determined with which effective tool radius the measurands Sa and Sq of the material measures are best met. The ideal effective radius for the application considered is between 50 and 75 μm.
AB - The calibration of areal surface topography measuring instruments is of high relevance to estimate the measurement uncertainty and to guarantee the traceability of the measurement results. Calibration structures for optical measuring instruments must be sufficiently small to determine the limits of the instruments. Besides other methods, micro-milling is a suitable process for manufacturing areal material measures. For the manufacturing by micro-milling with ball end mills, the tool radius (effective cutter radius) is the corresponding limiting factor: if the tool radius is too large to penetrate the concave profile details without removing the surrounding material, deviations from the target geometry will occur. These deviations can be detected and excluded before experimental manufacturing with the aid of a kinematic simulation. In this study, a kinematic simulation model for the prediction of the dimensional accuracy of micro-milled areal material measures is developed and validated. Subsequently, a radius study is conducted to determine how the tool radius r of the tool influences the dimensional accuracy of an areal crossed sinusoidal (ACS) geometry according to ISO 25178-70 [1] with a defined amplitude d and period length p. The resulting theoretical surface texture parameters are evaluated and compared to the target values. It was shown that the surface texture parameters deviate from the nominal values depending on the effective cutter radius used. Based on the results of the study, it can be determined with which effective tool radius the measurands Sa and Sq of the material measures are best met. The ideal effective radius for the application considered is between 50 and 75 μm.
KW - Kinematic simulation
KW - material measures
KW - Micro-milling
UR - http://www.scopus.com/inward/record.url?scp=85110218344&partnerID=8YFLogxK
U2 - 10.1007/s00170-021-07629-8
DO - 10.1007/s00170-021-07629-8
M3 - Article
AN - SCOPUS:85110218344
VL - 116
SP - 3087
EP - 3102
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
SN - 0268-3768
ER -