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<p>Micro-milling is essential in contemporary manufacturing, particularly for precision machining of components in materials like AA2024 aluminum alloy, widely used in aviation. This study investigates the influence of machining parameters—depth of cut, spindle speed, and feed speed—on surface roughness and burr formation using a 0.8-mm micro-end mill coated with aluminum titanium nitride (AlTiN). This study also evaluates machining forces under varied parameters to assess their behavior under the plowing effect. These insights advance micro-milling techniques, crucial for leveraging miniaturization advantages in modern manufacturing. The results showed that increasing the depth of cut from 0.1 to 0.15 mm often improves surface roughness, attributed to mitigating the plowing effect near the minimum uncut thickness. Optical and scanning electron microscopy elucidate aluminum oxide formation due to thermal and mechanical stresses, crucial for understanding micro-scale material behavior. Detailed examination of chip morphology confirms that feed speeds of 20 and 30 mm/min induce the plowing effect, impacting surface integrity.</p>

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Analysis of cutting parameter influence on micro-milling of AA2024 alloy with TiAlN-F tool

  • 期刊论文

  • 发表日期：

    2025年2月8日

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  • Rafael da Cunha Hamano,
  • Hector Reynaldo Meneses Costa,
  • Jose Luis Lopes da Silveira,
  • Karen Johanna Quintana Cuellar,
  • Matheus Campolina Mendes,
  • Tatiane de Campos Chuvas

摘要

Micro-milling is essential in contemporary manufacturing, particularly for precision machining of components in materials like AA2024 aluminum alloy, widely used in aviation. This study investigates the influence of machining parameters—depth of cut, spindle speed, and feed speed—on surface roughness and burr formation using a 0.8-mm micro-end mill coated with aluminum titanium nitride (AlTiN). This study also evaluates machining forces under varied parameters to assess their behavior under the plowing effect. These insights advance micro-milling techniques, crucial for leveraging miniaturization advantages in modern manufacturing. The results showed that increasing the depth of cut from 0.1 to 0.15 mm often improves surface roughness, attributed to mitigating the plowing effect near the minimum uncut thickness. Optical and scanning electron microscopy elucidate aluminum oxide formation due to thermal and mechanical stresses, crucial for understanding micro-scale material behavior. Detailed examination of chip morphology confirms that feed speeds of 20 and 30 mm/min induce the plowing effect, impacting surface integrity.