scholarly journals Investigation on the size effect in micro end milling considering the cutting edge radius and the workpiece material

2021 ◽  
Vol 12 (1) ◽  
pp. 487-499
Author(s):  
Yang Li ◽  
Xiang Cheng ◽  
Guangming Zheng ◽  
Huanbao Liu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Chip Morphology ◽  
Cutting Edge ◽  
Workpiece Material ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Element Simulation ◽  
Cutting Experiment ◽  
Cutting Mechanisms

Abstract. Previous research has found that the peripheral and end cutting edges of the cutter had different cutting mechanisms in the micro end cutting process considering the size effect. This investigation is a further study on this point considering the cutting edge radius of the cutter and the material of the workpiece based on the methods of finite element simulation and the micro end cutting experiment. This study adopts a combination of simulation and experiment research methods and the cutting edge radius and the workpiece material as two variables. Considering the cutting mechanisms of the peripheral cutting edge and the end cutting edge are different, the peripheral cutting edge and the end cutting edge are studied respectively. Meanwhile, the minimum undeformed chip thickness (MUCT) value is determined in three ways, chip morphology, cutting force, and surface roughness, so the final result obtained by comparing three kinds of results has a very important reference value. Not only are the chip morphology obtained by finite element simulation and the surface roughness obtained by the micro end cutting experiment used to identify the MUCT value, but also the cutting force. The simulation and experimental results show that the cutting force can be used to identify the MUCT value for the peripheral cutting edge, but it cannot be used for the end cutting edge. The MUCT value increases with the increase of the cutting edge radius, no matter which process it is. The material property has some effects on the MUCT value; even the cutting parameters and the cutting edge radius remain unchanged for the peripheral cutting edge. However, the material property has no effect on the MUCT value for the end cutting edge. In this study, the influence of important variables on MUCT is studied as much as possible to reflect a real application situation.

Study on micro cutting fundamentals considering the cutting edge radius and the workpiece material in micro end milling

2020 ◽  
pp. 095440892094602
Author(s):  
Yang Li ◽  
Xiang Cheng ◽  
Siying Ling ◽  
Guangming Zheng ◽  
Huanbao Liu ◽  
...  
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Micro Cutting ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Micro End Milling

Previous studies found that the peripheral cutting edge and end cutting edge in micro end milling had different cutting phenomena considering the size effect in micro cutting processes. This paper is a further study on this point considering different workpiece materials and cutting edge radii. Finite element simulations have been conducted to determine the minimum undeformed chip thickness (MUCT) by the chip morphology and the results are verified by micromilling experiments. Both the simulations and experiments show that the MUCT of the peripheral cutting edge and the end cutting edge are different even if the cutting edge radii remain unchanged. The MUCT is directly proportional to the cutting edge radius. Material properties also have some effects on the MUCT of the peripheral cutting edge. But it has limited effects on that of the end cutting edge. The results indicate that the feed engagement other than the axial depth of cut should be carefully selected in micro end milling when considering different workpiece materials.

Investigation on Mechanism of Ultra-Smoothed Surface with a Micro Slot on the Flank Face in Micro Cutting

2014 ◽  
Vol 651-653 ◽  
pp. 764-767
Author(s):  
Tao Zhang ◽  
Hou Jun Qi ◽  
Gen Li
Keyword(s):  
Surface Roughness ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Back Side ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Flank Face ◽  
Side Flow

Micro cutting is a promising manufacturing method to obtain good surface integrity. Surface roughness shows size effect when the uncut chip thickness is smaller than the cutting edge radius. A special micro slot on the flank face of cutting tools was manufactured with discharge. Two groups of micro orthogonal cutting were conducted. The surface roughness of machined surface was measured and compared to each other. The results show that surface roughness decreases first and then increases with the ratio of uncut chip thickness to cutting edge radius. The surface machined with micro slot is better than that of without micro slot due to the micro slot restrain the back side flow of work piece based on the finite element model.

scholarly journals Investigation of the Effect of End Mill-Geometry on Roughness and Surface Strain-Hardening of Aluminum Alloy AA6082

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3078
Author(s):  
Pavel Filippov ◽  
Michael Kaufeld ◽  
Martin Ebner ◽  
Ursula Koch
Keyword(s):  
Surface Roughness ◽  
Strain Hardening ◽  
Cutting Edge ◽  
Surface Strain ◽  
Micro Milling ◽  
End Mill ◽  
Cutting Edge Radius ◽  
Hardened Zone ◽  
Edge Radius ◽  
Machined Surfaces

Micro-milling is a promising technology for micro-manufacturing of high-tech components. A deep understanding of the micro-milling process is necessary since a simple downscaling from conventional milling is impossible. In this study, the effect of the mill geometry and feed per tooth on roughness and indentation hardness of micro-machined AA6082 surfaces is analyzed. A solid carbide (SC) single-tooth end-mill (cutting edge radius 670 nm) is compared to a monocrystalline diamond (MD) end-mill (cutting edge radius 17 nm). Feed per tooth was varied by 3 μm, 8 μm and 14 μm. The machined surface roughness was analyzed microscopically, while surface strain-hardening was determined using an indentation procedure with multiple partial unload cycles. No significant feed per tooth influence on surface roughness or mechanical properties was observed within the chosen range. Tools’ cutting edge roughness is demonstrated to be the main factor influencing the surface roughness. The SC-tool machined surfaces had an average Rq = 119 nm, while the MD-tool machined surfaces reached Rq = 26 nm. Surface strain-hardening is influenced mainly by the cutting edge radius (size-effect). For surfaces produced with the SC-tool, depth of the strain-hardened zone is higher than 200 nm and the hardness increases up to 160% compared to bulk. MD-tool produced a thinner strain-hardened zone of max. 60 nm while the hardness increased up to 125% at the surface. These findings are especially important for the high-precision manufacturing of measurement technology modules for the terahertz range.

Finite Element Simulation of Minimum Cutting Thickness in Micro-Cutting

2016 ◽  
Vol 861 ◽  
pp. 50-55 ◽  
Author(s):  
Pu Zhang ◽  
Hong Tao Zhu ◽  
Chuan Zhen Huang ◽  
Hong Liang Tang ◽  
Yang Yao ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Feed Rate ◽  
Finite Element Simulations ◽  
Cutting Edge ◽  
Workpiece Material ◽  
Micro Cutting ◽  
Cutting Edge Radius ◽  
Element Simulation ◽  
Order Of Magnitude

The cutting edge radius and cutting thickness as well as feed rate are in the same order of magnitude in micro-cutting. So it will appear a situation that the chip cannot be formed when the cutting thickness is less than a certain value which is the minimum cutting thickness. It is possible to find a method that can determine the minimum cutting thickness in the finite element simulation of micro-cutting according. In this paper, a series of finite element simulations of different workpiece materials in micro-cutting are carried out and several different minimum cutting thicknesses are obtained. It is shown that the minimum cutting thickness is related to the workpiece material in micro-cutting. When the workpiece materials are different, the minimum cutting thicknesses obtained are also different in micro-cutting.

scholarly journals An Improved Cutting Force Model in Micro-milling Considering the Comprehensive Effect of Tool Runout, Size Effect and Tool Wear

2021 ◽  
Author(s):  
Tongshun Liu ◽  
Yayun Liu ◽  
Kedong Zhang
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Cutting Force ◽  
Cutting Edge ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Tool Runout ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract Tool runout, cutting edge radius-size effect and tool wear have significant impacts on the cutting force of micro-milling. In order to predict the micro-milling force and the machining performance related to the cutting force, it is necessary to establish a cutting force model including tool runout, cutting edge radius and tool wear. In this study, an instantaneous uncut thickness (IUCT) model considering tool runout, a nonlinear shear/ploughing coefficient model including cutting-edge radius and a friction force coefficient model embedded with flank wear width, are constructed respectively. By integrating the IUCT, the nonlinear shear/ploughing coefficient and the friction force coefficient, a comprehensive micromilling force model including the tool runout, size effect and tool wear is derived. Experiment results show that the proposed comprehensive model is efficient to predict the micro milling force.

FE analysis of the effects of process representations on the prediction of residual stresses and chip morphology in the down-milling of Ti6Al4V

2021 ◽  
pp. 1-40
Author(s):  
Nejah Tounsi ◽  
Tahany El-Wardany
Keyword(s):  
Residual Stresses ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Milling Process ◽  
Cutting Edge ◽  
Uncut Chip Thickness ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract In part II of these two-part papers, the effects of four FEM representations of the milling process on the prediction of chip morphology and residual stresses (RS) are investigated. Part II focuses on the milling of conventional uncut chip thickness h with finite cutting edge radius and flank wear, while part I of these two-part papers has reported on the results in the case of milling small uncut chip thickness in the micrometre range with finite cutting edge radius. Two geometric models of the flank-wear land composed of flat and curved wear land are proposed and assessed. The four process representations are: i) orthogonal cutting with flat wear land and with the mean uncut chip thickness h ¯; ii) orthogonal cutting with flat wear land and with variable h, which characterises the down-milling process and which is imposed on a flat surface of the final workpiece; iii) modelling the true kinematics of the down milling process with flat wear land and iv) modelling the true kinematics of the down milling process with curved wear land. They are designated as Cte-h, Var-h, True-h and True-h*. The effectiveness of these representations is assessed when milling Ti6Al4V with a flank-wear land of VB = 200µm.

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