Simulation and Experimental Study on Size Effect in Steel Micro Milling Machining Process

Abstract

Size effect is a critical factor that needs to be considered when conducting micro mechanical machining processes. In this paper, a cutting process simulation technology is used to simulate a single tooth’s engagement with workpiece from the entry point to the exit point in a slot milling operation. The obtained specific cutting forces from simulation are employed to analyze the size effect and the minimum chip thickness with variable radii of tool edges. Micro machining experiments with different machining conditions are implemented by use of a high speed and high precision machining spindle to investigate the size effect on machined surface integrity and burr width. The optimal cutting parameters have been analyzed based on the simulation and cutting test results.

Machinability experimental study of sintered alumina (Al2O3) ceramics material by chemical vapor deposition diamond coating milling tools

“…Building directly from his research results, if it is possible to cut below the size of the grain, then the material will be more likely to slip along its slip planes as opposed to its fracture planes. 26–28 So, it is desired to keep the feed below the grain size to realize the ductile regime machining for the alumina ceramic studied in this research.…”

Cutting Tool Run out Considered Cutting Force Estimation in Micro Milling Processes

“…The elastic recovery S is the material's deformation on the flank face, which is expressed as Equation 25 according to the literatures [5] and [15,16,17]. The elastic recovery rate is estimated by Equation 26; where the t min (µm) is the minimum thickness of the cut and the t e (µm) is the reference thickness of cut.…”