An experimental study of micro-end-milling operations

Cutting tools less than 2mm diameter can be considered as micro-tool. Microtools are used in variety of applications where precision and accuracy are indispensable. In micro-machining operations, a small amount of material is removed and very small cutting forces are created. The small cross sectional area of the micro-tools drastically reduces their strength and makes their useful life short and unpredictable; so cutting parameters should be selected carefully to avoid premature tool breakage. The main objective of this study is to develop new techniques to select the optimal cutting conditions with minimum number of experiments and to evaluate the tool wear in machining operations. Several experimental setups were prepared and used to investigate the characteristics of cutting force and AE signals during the micro-end-milling of different materials including steel, aluminum and graphite electrodes. The proposed optimal cutting condition selection method required fewer experiments than conventional approaches and avoided premature tool breakage. The developed tool wear monitoring technique estimated the used tool life with ±10% accuracy from the machining data collected during the end-milling of non-metal materials

Plasma Cleaning of LCLS-II-HE verification cryomodule cavities

Plasma cleaning is a technique that can be applied in superconducting radio-frequency (SRF) cavities in situ in cryomodules in order to decrease their level of field emission. We developed the technique for the Linac Coherent Light Source II (LCLS-II) cavities and we present in this paper the full development and application of plasma processing to the LCLS-II High Energy (HE) verification cryomodule (vCM). We validated our plasma processing procedure on the vCM, fully processing four out of eight cavities of this CM, demonstrating that cavities performance were preserved in terms of both accelerating field and quality factor. Applying plasma processing to this clean, record breaking cryomodule also showed that no contaminants were introduced in the string, maintaining the vCM field emission-free up to the maximum field reached by each cavity. We also found that plasma processing eliminates multipacting (MP) induced quenches that are typically observed frequently within the MP band field range. This suggests that plasma processing could be employed in situ in CMs to mitigate both field emission and multipacting, significantly decreasing the testing time of cryomodules, the linac commissioning time and cost and increasing the accelerator reliability.Comment: 11 pages, 10 figure