Identification of factors that dominate size effect in micro-machining

Machinability study of steels in precision orthogonal cutting

“…A fresh cutting edge was used for each test, therefore, tool wear was considered negligible throughout the "size effect" is identified as critical in defining process performance. Size effects refers to the phenomenon whereby the reduction of the undeformed chip thickness to levels below the cutting edge radius, or gain size of the workpiece material begins to influence workpiece material deformation mechanisms, chip formation and flow 7 . Davim et al 8 compared finite element model (FEM) simulations with experimental and analytical findings concerning precision radial turning of AISI D2 steel using uncoated carbide cutting tools.…”

Micro-cutting of single-crystal metal: Finite-element analysis of deformation and material removal

“…When cutting was performed along the 0° direction (i.e. [1][2][3][4][5][6][7][8][9][10] orientation), slip systems activated in the FCC crystallographic structure were symmetrical with respect to it. Therefore, in the FE simulation, the chip separated from the work-piece symmetrically.…”

“…A component in the micro-scale exhibits a different mechanical response to that observed in its macro-scale counterpart [4,5]; consequently, its cutting response in the micro-scale also differs significantly. For example, cutting forces and chip morphology were found to depend on crystal orientation in several experimental studies on micromachining of single-crystal metals [6,7]. To better understand the process of local deformation and material removal at a tool-work-piece interface in a micromachining process, a thorough analysis of cutting mechanics at grain level is required [7][8][9].…”

“…For example, cutting forces and chip morphology were found to depend on crystal orientation in several experimental studies on micromachining of single-crystal metals [6,7]. To better understand the process of local deformation and material removal at a tool-work-piece interface in a micromachining process, a thorough analysis of cutting mechanics at grain level is required [7][8][9].…”

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

“…Ucun et al (2013) focused on tool wear research during the Inconel 718 micro-milling process. Mian et al (2011) found both chip thickness and cutting velocity is main factor that affect the micro-machining size effect. Cutting forces determine the power consumption and deformation of system during processing, meanwhile, they directly affect the generation of cutting heat, tool wear, tool breakage, tool life and machining accuracy.…”