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Optimization of micromachining operation for particle reinforced UHMWPE composites

Sofuoğlu Mehmet Alper, Gürgen Selim

Archives of Civil and Mechanical Engineering

2022

Vol. 22, no. 3

art. no. e138

Unlike metals, polymers are highly affected by the heat generation during the machining of the workpiece, because the thermal conductivity of polymers are considerably lower than metals, and therefore heat is much more effective in the cutting zone. If the appropriate cutting parameters are not selected, the polymers become excessively deformed and the final part has high surface roughness, dimensionally large burr formation, or dimensional deviations. Machining of polymers ultra-high molecular weight polyethylene (UHMWPE) is quite common in industrial applications. In this study, the effect of SiC fillers on the machinability of UHMWPE polymer composite was investigated. First, different samples were produced using different filler sizes (1 μm, 50 μm, and 100 μm) and different filler amounts (1%, 3%, 5%). Micro-milling tests were carried out at a constant feed rate (70 mm/min), constant cutting depth (0.1 mm) and spindle speeds (1200, 2800, and 4400 rpm). Tool overhang lengths were selected as 10, 15, and 20 mm. During the experiments, the surface/burr shapes, cutting temperatures and cutting forces were observed. In general, it is observed that SiC filler reduces cutting forces and cutting temperatures. In the further stage of the study, Taguchi analysis was performed in the light of different SiC filler sizes, filler amounts, rotational speeds, and tool overhang lengths.