Determination of minimum uncut chip thickness and size effects in micro-milling of P-20 die steel using surface quality and process signal parameters

2020 ◽  
Vol 106 (11-12) ◽  
pp. 4675-4691 ◽  
Author(s):  
Priyabrata Sahoo ◽  
Karali Patra ◽  
Tibor Szalay ◽  
Aleksandr A. Dyakonov
Keyword(s):  
Surface Quality ◽  
Size Effects ◽  
Chip Thickness ◽  
Micro Milling ◽  
Uncut Chip Thickness ◽  
Die Steel ◽  
Signal Parameters ◽  
Minimum Uncut Chip Thickness

scholarly journals Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model

Micromachines ◽  
2021 ◽  
Vol 12 (12) ◽  
pp. 1495
Author(s):  
Tongshun Liu ◽  
Kedong Zhang ◽  
Gang Wang ◽  
Chengdong Wang
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Uncut Chip Thickness ◽  
Milling Force ◽  
Minimum Uncut Chip Thickness ◽  
Cutting Force Coefficient ◽  
Milling Force Model

The minimum uncut chip thickness (MUCT), dividing the cutting zone into the shear region and the ploughing region, has a strong nonlinear effect on the cutting force of micro-milling. Determining the MUCT value is fundamental in order to predict the micro-milling force. In this study, based on the assumption that the normal shear force and the normal ploughing force are equivalent at the MUCT point, a novel analytical MUCT model considering the comprehensive effect of shear stress, friction angle, ploughing coefficient and cutting-edge radius is constructed to determine the MUCT. Nonlinear piecewise cutting force coefficient functions with the novel MUCT as the break point are constructed to represent the distribution of the shear/ploughing force under the effect of the minimum uncut chip thickness. By integrating the cutting force coefficient function, the nonlinear micro-milling force is predicted. Theoretical analysis shows that the nonlinear cutting force coefficient function embedded with the novel MUCT is absolutely integrable, making the micro-milling force model more stable and accurate than the conventional models. Moreover, by considering different factors in the MUCT model, the proposed micro-milling force model is more flexible than the traditional models. Micro-milling experiments under different cutting conditions have verified the efficiency and improvement of the proposed micro-milling force model.

An Assessment, Definition, and Determination of the Minimum Uncut Chip Thickness of Microcutting and Impact on Machining New Powder Metallurgy Nickel-Based Superalloys

2011 ◽  
Author(s):  
Z. Y. Shi ◽  
Z. Q. Liu ◽  
Y. B. Guo
Keyword(s):  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Chip Thickness ◽  
Critical Value ◽  
Uncut Chip Thickness ◽  
Minimum Uncut Chip Thickness ◽  
Process Mechanics ◽  
Art Research ◽  
Future Work

The uncut chip thickness is comparable to the cutting edge radius in micromachining. If the uncut chip thickness is less than a critical value, there will be no chip formation. This critical value is termed as the minimum uncut chip thickness (MUCT). Although minimum uncut chip thickness has been well defined in orthogonal cutting, it is often poorly understood in practical complex turning and milling processes. This paper presents an analysis of the state-of-art research on minimum uncut chip thickness in precision micro-machining. The numerical and experimental methods to determine MUCT values and their effects on process mechanics and surface integrity in microcutting will be critically assessed in this paper. A set of definitions of minimum uncut chip thickness for three-dimensional turning and milling processes are presented. In addition, a detailed discussion on the characteristics of different methods to determine minimum uncut chip thickness and several unsolved problems are proposed for the future work.

scholarly journals Estimation of Minimum Uncut Chip Thickness during Precision and Micro-Machining Processes of Various Materials—A Critical Review

Materials ◽  
2021 ◽  
Vol 15 (1) ◽  
pp. 59
Author(s):  
Szymon Wojciechowski
Keyword(s):  
Critical Review ◽  
Chip Thickness ◽  
Micro Machining ◽  
Machining Processes ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Thickness Estimation ◽  
Minimum Uncut Chip Thickness ◽  
Ultra Precision

Evaluation of the phenomena characterizing the chip decohesion process during cutting is still a current problem in relation to precision, ultra-precision, and micro-machining processes of construction materials. The reliable estimation of minimum uncut chip thickness is an especially challenging task since it directly affects the machining process dynamics and formation of a surface topography. Therefore, in this work a critical review of the recent studies concerning the determination of minimum uncut chip thickness during precision, ultra-precision, and micro-cutting is presented. The first part of paper covers a characterization of the precision, ultra-precision, and micro-cutting processes. In the second part, the analytical, experimental, and numerical methods for minimum uncut chip thickness estimation are presented in detail. Finally, a summary of the research results for minimum uncut chip thickness estimation is presented, together with conclusions and a determination of further research directions.

Numerical Modeling of Minimum Uncut Chip Thickness for Micromachining With Different Rake Angle

2011 ◽  
Author(s):  
Z. Y. Shi ◽  
Z. Q. Liu
Keyword(s):  
Numerical Modeling ◽  
Cutting Tool ◽  
Chip Thickness ◽  
Rake Angle ◽  
Arbitrary Lagrangian Eulerian ◽  
Uncut Chip Thickness ◽  
Minimum Uncut Chip Thickness ◽  
Effective Rake Angle ◽  
The Relationship

In micromachining, when the undeformed chip thickness becomes comparable to the edge radius of the cutting tool, the effective rake angle becomes to be negative and has significant effect on the determination of the minimum uncut chip thickness. The determination of the minimum uncut chip thickness is essential in micro machining in order to achieve desired surface integrity and accuracy. In this paper, an Arbitrary Lagrangian Eulerian (ALE)-based numerical modeling is proposed to determine the minimum uncut chip thickness for Copper by changing the cutting tool’s nominal rake angle. According to the relationship between the minimum uncut chip thickness and the effective rake angle, a mathematical model that reflects the relationship between the effective rake angle and the nominal rake angle is established.

scholarly journals Microstructure-Based 3D FE Modeling for Micro Cutting Ferritic-Pearlitic Carbon Steels

2014 ◽  
Author(s):  
M. Abouridouane ◽  
F. Klocke ◽  
D. Lung
Keyword(s):  
Size Effects ◽  
Chip Thickness ◽  
Rake Angle ◽  
Carbon Steels ◽  
Micro Milling ◽  
Fe Model ◽  
Two Phase ◽  
Workpiece Material ◽  
Micro Cutting ◽  
Feed Force

The mechanics of the cutting process on the microscopic level differ fundamentally from the conventional macro cutting. For example, the tool edge radius influences the cutting mechanism in micro machining significantly with regard to the effective rake angle, the minimum chip thickness, the dominance of ploughing, and the related elasto-plastic deformation of the workpiece material. These phenomena, known as size effects, have a profound impact on the cutting force, process stability, and resulting surface finish in micro cutting. Therefore, microstructural effects in microscale cutting require quite different assumptions to be made concerning underlying material behaviour during micro cutting and have led to the need for new modeling approaches to account for such effects. This paper presents a three-dimensional finite element approach to incorporate microstructure into micro cutting simulation based on the concept of a representative volume element (RVE) and constitutive material modeling as well as using the Lagrangian formulation proposed in the implicit FE code Deform 3D™. Micro drilling and micro milling tests using solid carbide tools with different diameters (d = 50 μm − 1 mm) were performed on ferrite-pearlite two-phase steel AISI 1045 for the verification of the developed 3D multiphase FE computation model regarding chip formation, feed force, and torque. The developed 3D multiphase FE model was successfully used to predict size effects in micro cutting.

Sign in / Sign up

Export Citation Format

Share Document