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dc.rights.licenseRestricted to current Rensselaer faculty, staff and students. Access inquiries may be directed to the Rensselaer Libraries.
dc.contributorSamuel, Johnson
dc.contributorWalczyk, Daniel F.
dc.contributorMishra, Sandipan
dc.contributor.authorAltman, Robert George
dc.date.accessioned2021-11-03T08:44:20Z
dc.date.available2021-11-03T08:44:20Z
dc.date.created2017-01-19T09:02:48Z
dc.date.issued2016-12
dc.identifier.urihttps://hdl.handle.net/20.500.13015/1863
dc.descriptionDecember 2016
dc.descriptionSchool of Engineering
dc.description.abstractThe magnetic field-based process suffers from shortcomings such as: poor effectiveness at removing BUEs, an inability to be implemented in-situ due to the size of the electromagnet, and an apparent decrease in tool life, which is a result of fatigue loading caused by the alternating magnetic field. These shortcomings were successfully overcome by the planetary motion-based three-stage intervention process. This second process consists first of the mechanical removal of large BUEs, followed by polishing of the tool in an abrasive slurry to remove the micro-scale BUEs. Finally, the tool is cleaned using a non-woven fibrous mat to remove the slurry debris. An on-machine implementation of this in-process intervention is demonstrated followed by a study of its influence on key micro-machining outcomes such as tool wear, cutting forces, part geometry and burr formation. In general, all relevant machining measures were found to improve significantly with the intervention. The key attributes of this intervention that makes it viable for micro-machining processes include (i) An experimental setup that can be implemented within the working volume of the micro-scale machine tool; (ii) No removal of the tool from the spindle, which ensures that the intervention does not change critical process parameters such as tool runout and offset values; and (iii) Implementation in the form of canned G-code subroutines dispersed within the regular micro-machining operation.
dc.description.abstractThis thesis is focused on developing an in-process intervention technique that mitigates the formation of built-up edges (BUEs) during micro-milling of aluminum. Two different approaches were explored: first, a magnetic field-based process that relies on the use of an abrasive-laden ferromagnetic solution to remove the BUEs attached to the tool, and second, a planetary motion-based three-stage intervention process that uses an abrasive slurry to mechanically remove the BUEs.
dc.language.isoENG
dc.publisherRensselaer Polytechnic Institute, Troy, NY
dc.relation.ispartofRensselaer Theses and Dissertations Online Collection
dc.subjectMechanical engineering
dc.titleIn-process intervention to mitigate built-up edge formation in micro-milling
dc.typeElectronic thesis
dc.typeThesis
dc.digitool.pid177924
dc.digitool.pid177925
dc.digitool.pid177926
dc.rights.holderThis electronic version is a licensed copy owned by Rensselaer Polytechnic Institute, Troy, NY. Copyright of original work retained by author.
dc.description.degreeMS
dc.relation.departmentDept. of Mechanical, Aerospace, and Nuclear Engineering


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