Micromachining Technique
Al 19000 alloy (IS: 733) in the form cylindrical rod having mean diameter 9.164 mm was taken as workpiece with the following chemical composition 0.1% Cu, 0.2% Mg, 0.5% Si, 0.7% Fe, 0.1 %Mn, 0.1%Zn, and balance %Al. This Aluminium alloy has a tensile strength of 147 N/mm2, elongation of 13.2% and its vickers hardness number is 42. Cermet insert with a rake angle (α) of 100 and a nose radius (re) of 100 µm was used as cutting tool. A CNC turning centre was used for conducting the experiments. The workpiece was electroplated with nickel for a thickness of 30 µm in order to remove the metal as minimum as possible in microns level. This is explained in the next section, under the heading of “Stages of micromachining process”. The bare workpiece …show more content…
Based on the model, the relationship between parameters in micromachining was derived and it is shown Figure 2. Using this theoretical model as given in following equations, the stagnant angle (θm), Minimum Uncut Chip Thickness (MUCT/hm) and Minimum Cutting Thickness (MCT) were found out for unplated aluminium rod. α = Л/2 - …show more content…
Finally, the aluminium rod was kept in the electrolytic bath for electroplating. The operating conditions are selected depending on the plating thickness that is 30 µm.
6. Electroplating was done.
Step 3. Measurement of Nickel plating thickness
The nickel plating thicknesses were measured by a gauge for coating thickness (MAKE: Metrix 25 FN). The plating thickness of rod is along the circumference at a regular interval of 45º. This measurement was repeated for the entire length of rod and plating profile was plotted as shown in Figure 3.
Step 4. : The microturning was carried out on the electroplated aluminium rod as per the experimental design. The MCTe and MUCT values for electroplated aluminium rod were predicted using the analytical model developed [28]. The MCTe value was also determined experimentally. The diameter of aluminium rod before plating and diameter of aluminium rod after machining were measured using Coordinates Measuring Machines (CMM). The lower plating thickness has been considered for analysis. The diameters were measured three times at various places and average value taken for analysis. The values predicted by the model and the values determined using experiments were compared. The values are shown in Table
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