Defined cutting edge preparation for process optimization in micro milling

微铣削工艺的特点是目标几何形状复杂，材料范围广，经济潜力大。微型铣刀失效的一个原因通常是切削刃的磨损，这是切削材料时高载荷的结果。确定的切削刃准备提供了稳定切削刃和减少磨损的方法。整个项目的目标是通过优化微铣削刀具来改善微铣削工艺，通过使用刀具的准备来优化微铣削刀具。展望了浸没式滚轧（工业上也称为拖曳光整）的最佳工艺参数和加工策略的实验和模拟探索和定义。通过对制备和未制备的微铣刀的磨损分析，获得了与工艺条件相关的最佳切削刃几何形状的基本知识。在第一个资助期，一开始就制定了微铣刀磨损分析的策略。随后，浸没式滚磨中的工艺参数被分析用于定义的切削刃制备，并生成回归模型。此外，还通过磨损和切削力分析确定了提高加工安全性的切削刃几何形状，并为创建浸入式滚轧模拟预测模型奠定了基础。在第二个供资期内，将完成预测模型，并对浸入式滚轧中的几何变化进行数值计算。此外，各种刀具涂层将被表征，并将确定涂层导致的切削刃几何形状的变化。该资助期的目标是探索和定义浸入式翻滚涂层预处理和后处理的加工策略。优化的涂层制备是为了减少切削刃的碎裂并增加涂层对切削刃的附着力。刀具后处理的目的是去除在通过电弧PVD进行涂层期间在刀具表面上出现的不需要的液滴。通过磨损和切削力分析，知识的行为所产生的切削刃的几何形状取决于工艺条件，将获得最后的实验结果的两个资助期将用于定义优化的预处理和后处理策略的涂层。

The micro milling process is characterized by a target geometric complexity, a wide range of materials and a large economic potential. One reason for the failure of micro milling tools is usually the wear of the cutting edges, which occurs as a result of high loads when cutting the material. A defined cutting edge preparation provides an approach to stabilize the cutting edge and to reduce wear. The result is higher tool life and process stability.The aim of the overall project is the improvement of the micro milling process by optimizing the micro milling tools through using the preparation of the cutting tool. In the foreground is the experimental and simulative exploration and definition of the optimal process parameters and processing strategies of the immersed tumbling which is also known as drag finishing in the industry. By wear analysis of respectively prepared and unprepared micro milling tools, basic knowledge about the optimal cutting edge geometry in dependence of the process conditions will be obtained.In the first funding period, a strategy for metrological analysis of micro milling tools was worked out at the beginning. Subsequently, the process parameters in the immersed tumbling were analyzed for the defined cutting edge preparation and a regression model was generated. Furthermore, cutting edge geometries for increased process safety were identified by wear and cutting force analyses and the basics for the creation of a predictive model for the simulation of immersed tumbling were developed.In the second funding period, the prediction model will be completed and a numerical calculation of the geometrical change in the immersed tumbling will be made. Furthermore, various tool coatings will be characterized and the resulting change of the cutting edge geometry by coating will be determined. The objective of this funding period is the exploration and definition of machining strategies for the pre-processing and post-processing of coatings by the immersed tumbling. An optimized coating preparation is to reduce the chipping of the cutting edge and increase the coating adhesion to the cutting edge. The aim of the tool post-processing is the removal of unwanted droplets on the tool surface which occur during coating by arc PVD. Through the wear and cutting force analysis, knowledge about the behavior of generated cutting edge geometries depending on the process conditions will be obtained and finally the experimental results of both funding periods will be used for the definition of optimized pre-processing and post-processing strategies of coatings.