Design and fabrication of micro end mills for the machining of difficult-to-cut materials

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buir.advisorKarpat, Yiğit
dc.contributor.authorOliaei, Samad Nadimi Bavil
dc.date.accessioned2016-09-20T13:31:19Z
dc.date.available2016-09-20T13:31:19Z
dc.date.copyright2016-08
dc.date.issued2016-08
dc.date.submitted2016-09-09
dc.departmentDepartment of Mechanical Engineeringen_US
dc.descriptionCataloged from PDF version of article.en_US
dc.descriptionThesis (Ph.D.): Bilkent University, Mechanical Engineering, İhsan Doğramacı Bilkent University, 2016.en_US
dc.descriptionIncludes bibliographical references (leaves 257-278).en_US
dc.description.abstractMicromilling is a cost-e ective method of fabricating miniaturized components with complex, three-dimensional features made from di cult-to-cut materials. Microcutting tools are exposed to harsh conditions during machining of such materials, which leads to short tool life and thus a ects the economics of the process. The aim of this thesis is to develop a systematic approach to the design and fabrication of high-precision micro-cutting tools. Machining characteristics of three di erent di cult-to-cut materials–stainless steel, titanium alloy, and silicon–have been investigated using experimental techniques. The results reveal the importance of interaction between tool micro geometry and work material mechanical properties. This observation leads to the development of tailored micro-end mills which are designed and fabricated based on the requirements of the specific machining task. This study also examines in detail built-up edge, an important but usually overlooked issue in micromachining of ductile materials, which a ects the process forces, tool wear, and tool deflections. The protective e ect of built-up edge has been exploited by creating micro-dimples on the tool surface using electrical discharge machining. Its positive influence on tool performance has been demonstrated. As for the micromachining of silicon, the flow of cut material around the cutting edge is paramount in tool design. A novel tool design for machining of silicon has been proposed and its e ectiveness has been validated through experiments. It has been shown that the selection of proper process parameters together with tailored tool design may increase the productivity of micromachining and improve surface quality and dimensional accuracy of micro-scale parts.en_US
dc.description.degreePh.D.en_US
dc.description.statementofresponsibilityby Samad Nadimi Bavil Oliaei.en_US
dc.embargo.release2018-01-01
dc.format.extentxxi, 278 leaves : charts (some color)en_US
dc.identifier.itemidB154034
dc.identifier.urihttp://hdl.handle.net/11693/32243
dc.language.isoEnglishen_US
dc.publisherBilkent Universityen_US
dc.rightsinfo:eu-repo/semantics/openAccessen_US
dc.subjectMicromillingen_US
dc.subjectMicro cutting toolen_US
dc.subjectTitaniumen_US
dc.subjectPolycrystalline diamonden_US
dc.subjectDuctile mode machiningen_US
dc.titleDesign and fabrication of micro end mills for the machining of difficult-to-cut materialsen_US
dc.title.alternativeKesilmesi zor malzemelerin işlenmesi için mikro frezeleme takımlarının tasarım ve üretimien_US
dc.typeThesisen_US

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