SpringerLink
Log in

Chip formation analysis in micromilling operation

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In mechanical micromachining, understanding the chip formation mechanism is critical to optimize the machining parameters and improve the workpiece performance. In this work, the entire slot micromilling process on Al6061-T6 by one flute carbide cutter was simulated by means of finite element method (FEM). Under this machining parameters set, the chip was found to be segmented type. The simulation results matched with the experimental results on the burr and chip morphologies and the cutting force. The segmented chip formation process was described from the viewpoint of chip velocity. The variations of the tool chip contact length (l T ) and the shear band length (l S ) were studied in detail. The chip formation mechanism was studied quantitatively by means of hybrid analytical-FEM approach. Through calculating the chip moments, “tool rake moment” M Tool and “shear band moment” M Work, it has been found that the main reasons of the segmented chip formation are the variations of the l T and l S . The Arcona–Dow model (AD model) and Merchant model (MM model) were utilized to calculate the M Work respectively. The AD model performed better in the microscale than the MM model. In the segment generation occasion, the average chip velocity value in chip bending process was much greater than the one before chip bending, which was about the cutting speed. The chip root velocity was almost constant in the entire micromilling process, and the chip tip velocity increased greatly in the chip bending instant due to the chip angular acceleration. The chip angular acceleration was acquired, respectively, from FEM and the analytical method based on the M Tool and M Work_AD calculations. The agreement of these two approaches validated the correctness of the chip moments calculations. The results of this work were useful to understand the micromilling mechanism and improve the workpiece performances.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Dornfeld D, Min S, Takeuchi Y (2006) Recent advances in mechanical micromachining. Ann CIRP 55(2):745–768

    Article  Google Scholar 

  2. Alting L, Kimura F, Hansen H, Bissacco G (2003) Micro engineering. Ann CIRP 52(2): STC–O

    Google Scholar 

  3. Weule H, Huntrup V, Tritschler H (2001) Micro-cutting of steel to meet new requirements in miniaturization. Ann CIRP 50:61–64

    Article  Google Scholar 

  4. Bang Y, Lee K, Oh S (2005) 5-axis micro milling machine for machining micro parts. Int J Adv Manuf Technol 25:888–894

    Article  Google Scholar 

  5. Wang J, Gong Y, Abba G, Cao J, Shi J, Cai G (2007) Micro milling technologies for mems. In: Proceeding of 3rd MEMSTECH, Lviv-Polyana, 23–26 May 2007, pp 86–95

  6. Astakhov V, Shvets S, Osman M (1997) Chip structure classification based on mechanics of its formation. J Mater Process Technol 71(2):247–257

    Article  Google Scholar 

  7. Ueda K, Manabe K (1992) Chip formation mechanism in microcutting of an amorphous metal. Ann CIRP 41(1):129–132

    Article  Google Scholar 

  8. Lee K, Dornfeld D (2002) An experimental study on burr formation in micro milling aluminium and copper. Trans North Am Manuf Res Inst SME 30:255–262

    Google Scholar 

  9. Usui E, Shirakashi T (1982) Mechanics of machining from descriptive to predictive theory, on the art of cutting metals. ASME PED 7:13–35

    Google Scholar 

  10. Özel T, Altan T (2000) Process simulation using finite element method—prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling. Int J Mach Tools Manuf 40(5):713–738

    Article  Google Scholar 

  11. Özel T, Zeren E (2007) Finite element modeling the influence of edge roundness on the stress and temperature fields induced by high-speed machining. Int J Adv Manuf Technol 35:255–267

    Article  Google Scholar 

  12. Vogler M, DeVor R, Kapoor S (2004) On the modeling and analysis of machining performance in micro-endmilling, part I: surface generation. ASME J Manuf Sci Eng 126:684–693

    Google Scholar 

  13. Chuzhoy L, DeVor R, Kapoor S, Beaudoin A, Bammann D (2003) Machining simulation of ductile iron and its constituents. Part I: estimation of material model parameters and their validation. ASME J Manuf Sci Eng 125:181–191

    Article  Google Scholar 

  14. Simoneau A, Ng E, Elbestawi M (2006) Chip formation during microscale cutting of a medium carbon steel. Int J Mach Tools Manuf 46:467–481

    Article  Google Scholar 

  15. Dhanorker A, Özel T (2008) Meso/micro scale milling for micro-manufacturing. Int J Mechatron Manuf Syst 1:23–42

    Article  Google Scholar 

  16. Woon K, Rahman M, Fang F, Neo K, Liu K (2008) Investigations of tool edge radius effect in micromachining: a fem simulation approach. J Mater Process Technol 195:204–211

    Article  Google Scholar 

  17. Cheng K, Luo X, Ward R, Holt R (2003) Modeling and simulation of the tool wear in nanometric cutting. Wear 255(7–12):1427–1432

    Article  Google Scholar 

  18. Shi J, Liu C (2004) The influence of material models on finite element simulation of machining. ASME J Manuf Sci Eng 126(4):849–857

    Article  Google Scholar 

  19. Özel T (2006) The influence of friction models on finite element simulations of machining. Int J Mach Tools Manuf 46(5):518–530

    Article  Google Scholar 

  20. Friedrich C, Kulkarni V (2004) Effect of workpiece springback on micromilling forces. Microsyst Technol 10:472–477

    Article  Google Scholar 

  21. Arcona C, Dow T (1998) An empirical tool force model for precision machining. ASME J Manuf Sci Eng 120:700–707.

    Article  Google Scholar 

  22. Johnson G, Stryk R, Holmquist T, Beissel S (1996) User instruction for the 1996 version of the epic code. Tech. Rep., Alliant Techsystems Inc

  23. Özel T, Zeren E (2004) Determination of work material flow stress and friction properties for fea of machining using orthogonal cutting tests. J Mater Process Technol 153–154:1019–1025

    Article  Google Scholar 

  24. Trent E, Wright P (2000) Metal cutting, 4th edn. Butterworth-Heinemann, Woburn

    Google Scholar 

  25. Medaska M, Nowag L, Liang S (1999) Simultaneous measurement of the thermal and mechanical effectiveness of cutting fluid. J Mach Sci Technol 3(2):221–237

    Article  Google Scholar 

  26. Shaw M (1993) Chip formation in the machining of hardened steel. Ann CIRP 42(1):29–33

    Article  Google Scholar 

  27. Wang J, Gong Y, Abba G, Chen K, Shi J, Cai G (2008) Surface generation analysis in micro end-milling considering the influences of grain. Microsyst Technol 14(7):937–942

    Article  Google Scholar 

  28. Bil H, Kiliç S, Tekkaya A (2004) A comparison of orthogonal cutting data from experiments with three different finite element models. Int J Mach Tools Manuf 44(2):933–944

    Article  Google Scholar 

  29. Childs T, Maekawa K, Obikawa T, Yamane Y (2000) Metal machining: theory and applications. Arnold, London

    Google Scholar 

  30. Moufki A, Molinari A, Dudzinski D (1998) Modelling of orthogonal cutting with a temperature dependent friction law. J Mech Phys Solids 35(9):1092–1027

    Google Scholar 

  31. Merchant M (1945) Mechanics of the metal cutting process 1: orthogonal cutting and a type 2 chip. J Appl Physi 16(5):267–275

    Article  Google Scholar 

  32. Venuinod P, ** W (1996) Three-dimensional cutting force analysis based on the lower boundary of the shear zone. Part 1: single edge oblique cutting. Int J Mach Tools Manuf 36(3):307–323

    Article  Google Scholar 

  33. Dow T, Miller E, Garrard K (2004) Tool force and deflection compensation for small milling tools. Precis Eng 28:31–45

    Article  Google Scholar 

  34. Gong Y, Wang J, Abba G, Antoine J, Shi J (2008) Tool tip trajectories investigation and its influences in micromilling operation. In: 3rd IEEE International Conference on Nano/Micro Engineered and Molecular Systems, Sanya, 6–9 January 2008, pp 440–445

  35. Astakhov V (1998) Metal cutting mechanics. CRC, Boca Raton

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Laboratory of Advanced Manufacturing and Automation, Northeastern University, Shenyang, China

    **sheng Wang, Yadong Gong & Jiashun Shi

  2. Laboratoire de Génie Industriel et de Production Mécanique, Université de Paul Verlaine, Metz, France

    **sheng Wang, Gabriel Abba & Jean Francois Antoine

Authors
  1. **sheng Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yadong Gong
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Gabriel Abba
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jean Francois Antoine
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jiashun Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to **sheng Wang.

Additional information

This work is financial supported by Chinese 985-II foundation, Northeastern University outstanding PhD project foundation (200705), French Research Ministry, and Lorraine Region Council.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Wang, J., Gong, Y., Abba, G. et al. Chip formation analysis in micromilling operation. Int J Adv Manuf Technol 45, 430–447 (2009). https://doi.org/10.1007/s00170-009-1989-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-009-1989-8

Keywords

Search

Navigation