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.

Numerical Modeling of Minimum Uncut Chip Thickness for Micromachining with Different Work Materials

2014 ◽  
Vol 800-801 ◽  
pp. 402-407
Author(s):  
Lu Ning Liu ◽  
Zhen Yu Shi ◽  
Zhan Qiang Liu
Keyword(s):  
Numerical Modeling ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Material Behavior ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Arbitrary Lagrangian Eulerian ◽  
Uncut Chip Thickness ◽  
Workpiece Material ◽  
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. The parameters being considered in determination the minimum uncut chip thickness include the cutting tool geometry, workpiece material, cutting parameters and so on. In this paper, five different materials including OFHC Copper, Al 7050, AISI 4340, Ti-6Al-4V and IN 718 with unequal materials’ properties were investigated to find materials parameters’ effect on the minimum uncut chip thickness. An Arbitrary Lagrangian Eulerian (ALE)-based numerical modeling is proposed to determine the minimum uncut chip thickness for the five different materials by changing depth-of-cut. The Johnson-Cook (J-C) constitutive model is employed to describe the work material behavior. Results show that the flow stress of different materials has significant effect on the minimum uncut chip thickness.

Experimental investigation of a slip-line field model for a worn cutting tool

2013 ◽  
Vol 228 (8) ◽  
pp. 1398-1404 ◽  
Author(s):  
Alper Uysal ◽  
Erhan Altan
Keyword(s):  
Wear Rate ◽  
Slip Line ◽  
Field Model ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Line Field

In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

Influence of Depth of Cut on Contact Phenomenon in Micromachining

2014 ◽  
Vol 660 ◽  
pp. 8-12
Author(s):  
J.B. Saedon ◽  
Noor Aniza Norrdin ◽  
Mohd Azman Yahaya ◽  
N.H. Mohamad Nor ◽  
Mohd Zulhafiz Md Salih
Keyword(s):  
Cutting Tool ◽  
Chip Thickness ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Work Piece ◽  
Arbitrary Lagrangian Eulerian ◽  
Contact Phenomenon ◽  
Aisi D2 ◽  
Material Separation ◽  
Contact Distribution

Chip formation is a dynamic process that is often nonlinear in nature. A chip may not form when the depth of cut is less than a minimum chip thickness. It is aimed to investigate influence of depth of cut on contact phenomenon in micromachining. This paper presents a series of simulation works by finite element method on depth of cut effect on micromachining. A model is developed with consideration of the Johnson-Cook material and Arbitrary Lagrangian–Eulerian (ALE) method. In this work investigate the effect of depth of cut on the contact phenomenon during micromachining AISI D2. The results of the analysis are showed in aspects of interrelationship between material separation and frictional shear contact, distribution of stick-slide regions and contact stress on the work piece and cutting tool. It is found that the sticking and sliding was occurred on three zones as primary, secondary and tertiary shear zone. The contact phenomena can be showed around the tool edge radius where material flows around it and piles in front of the cutting tool through material separation. The investigation of contact phenomena inclusive under three criteria such as a/r < 1, a/r > 1 and a/r = 1 on positive rake angle.

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.

Sign in / Sign up

Export Citation Format

Share Document