An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining

Liu, Xinyu; DeVor, Richard E.; Kapoor, Shiv Gopal

doi:10.1115/1.2162905

Cited by 233 publications

(147 citation statements)

References 11 publications

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“…When feed per tooth is 0.7 μm, the cutting forces nearby have obvious trends of first increasing and then decreasing, so the minimum chip thickness is approximate f z = 0.7 μm during micro-milling Inconel 718. The cutting edge radius of the adopted cutter is approximate R = 2 μm, so f z / R ≈ 0.35, which consistent with the conclusion that the minimum chip thickness to tool edge radius ratio is approximate 0.2~0.4 (Liu et al, 2006). To reduce the cutting forces, it is advisable to avoid minimum chip thickness, so as to extend the tool life and to increase processing efficiency.…”

Section: Feed Per Tooth's Influence On Cutting Forcessupporting

confidence: 54%

Measurement-based modelling of cutting forces in micro-milling of Inconel 718

Lü

Zhang

Wang

et al. 2017

IJNM

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Due to its superior properties, nickel-based superalloy Inconel 718 can meet the requirements of micro parts with the high strength at high temperatures which have three-dimensional geometry structure like stepped surface, deep-hole, thin wall and so on. However, Inconel 718 is difficult to cut. Now, there are few researches on the cutting forces in micro-milling of Inconel 718, and the micro-milling mechanism of nickel-based superalloy is almost blank, while the prediction and control of micro-milling forces is important to reveal the micro-milling mechanism of nickel-based superalloy, to realise processing parameter optimisation, to reduce the tool wear, etc... To predict the cutting forces during micro-milling Inconel 718 process, coated carbide tools are used to micro-milling micro groove on Inconel 718, and the orthogonal type experiments are adopted. The influences of cutting parameters on cutting forces are studied. The micro-milling forces prediction model is built based on the experimental results, which can be used to predict the cutting forces during micro-milling of Inconel 718 nickel-based superalloy. To prove the validity of the built model, the significance test and fitting degree test are conducted.Keywords: micro; milling; forces; parameters; Inconel 718.Reference to this paper should be made as follows: Lu, X., Jia, Z., Wang, H., Hu, X., Li, G. and Si, L. (2017)

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Section: Feed Per Tooth's Influence On Cutting Forcessupporting

confidence: 54%

Measurement-based modelling of cutting forces in micro-milling of Inconel 718

Lü

Zhang

Wang

et al. 2017

IJNM

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“…Changed surface appearances from clean cut to burnished have been reported [4,5]. Experimental and theoretical studies have indicated the critical value of a c /r e to be between 0.1 and 0.5, depending on material machined and cutting conditions [6,7]. But little has been reported on variation of surface roughness with a c /r e .…”

Section: Introductionmentioning

confidence: 99%

The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

Childs

Dornfeld

Lee

et al. 2008

CIRP Journal of Manufacturing Science and Technology

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“…In recent years, many slip-line field models have been specifically developed for the microscale [9][10][21][22][23][24][25][26][27][28][29] and all of them consider a rounded tool edge.…”

Section: State Of the Artmentioning

confidence: 99%

“…Waldorf et al [9][10], Liu et al [23][24][25], Karpat et al [26], Yoon et al [27] and Ozturk et al [29];…”

mentioning

confidence: 99%

Applicability of an orthogonal cutting slip-line field model for the microscale

Rebaioli

Biella

Annoni

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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Mechanical micromachining is a very flexible and widely exploited process, but its knowledge should still be improved since several incompletely explained phenomena play a role on the microscale chip removal (e.g. "minimum chip thickness effect", microstructure influence on cutting forces, stable built-up edge, etc.). Several models have been developed to describe the machining process, but only some of them take into account a rounded-edge tool, which is a typical condition in micromachining. Among these models, the slip-line field model developed by Waldorf for the macroscale allows to separately evaluate shearing and ploughing force components in orthogonal cutting conditions, therefore it is suitable to predict cutting forces when a large ploughing action occurs, as in micromachining. The present study aims at demonstrating how this model is suitable also for micromachining conditions. In order to achieve this goal, a clear, modular and repeatable procedure has been developed for objectively validating its cutting and feed force prediction performance at low uncut chip thickness (less than 50 µm) and relatively higher cutting edge radius. The proposed procedure makes the model generally applicable after a suitable and 2 non-extensive calibration campaign. The present paper shows how calibration experiments can be selected among the available database of cutting trials basing on the model force prediction capability. Final validation experiments have been used to show how the model is robust to a cutting speed variation even if the cutting speed is not among the model quantities. A suitable set-up, especially designed for microturning conditions, has been used in this research to measure forces and chip thickness. Tests have been carried out on 6082-T6 Aluminum alloy with different cutting speeds and different ratios between uncut chip thickness and cutting edge radius.

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An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining

Cited by 233 publications

References 11 publications

Measurement-based modelling of cutting forces in micro-milling of Inconel 718

Measurement-based modelling of cutting forces in micro-milling of Inconel 718

The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

Applicability of an orthogonal cutting slip-line field model for the microscale

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