Abstract
To optimize the machining process, finding the minimum uncut chip thickness is of paramount importance in micro-scale machining. However, strong dependency of the minimum uncut chip thickness to the tool geometry, workpiece material, tool-work friction, and process condition makes its evaluation complicated. The paper focuses on determination of the minimum uncut chip thickness experimentally during micro-end milling of titanium alloy Ti-6Al-4V with respect to influences of cutting parameters and lubricating systems. Experiments were carried out on a CNC machining center Kern Evo with two flute end mills of 0.8 and 2 mm diameters being used in the tests for micro- and macro-milling, respectively. It was found that the micro-milling caused more size effect than macro-milling due to higher surface micro-hardness and specific cutting forces. The specific cutting force depended strongly on feed rate (f z) and lubricating system, followed by depth of cut (a p) and cutting speed (v c), mainly in the micro-scale. All output parameters were inversely proportional to the specific cutting force. Finally, depending on different process parameters during micro-milling of Ti-6Al-4V, the minimum uncut chip thickness was found to vary between 0.15 and 0.49 of the tool edge radius.
Similar content being viewed by others
Change history
14 August 2021
A Correction to this paper has been published: https://doi.org/10.1007/s00170-021-07852-3
References
Chae J, Park SS, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46(3–4):313–332. https://doi.org/10.1016/j.ijmachtools.2005.05.015
Basuray PK, Misra BK, Lal GK (1977) Transition from ploughing to cutting during machining with blunt tools. Wear 43(3):341–349
Son SM, Lim HS, Ahn JH (2005) Effect of the friction coefficient on the minimum cutting thickness in micro cutting. Int J Mach Tools Manuf 45:529–535
Malekian M, Mostofa MG, Park SS, Jun MBG (2012) Modeling of minimum uncut chip thickness in micro machining of aluminum. J Mater Process Technol 212:553–559
Yuan ZJ, Zhou M, Dong S (1996) Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining. J Mater Process Technol 62:327–330
Liu X, DeVor RE, Kapoor SG (2006) An analytical model for the prediction of minimum chip thickness in micromachining. J Manuf Sci Engng Trans ASME 128(2):474–481
Vogler MP, DeVor RE, Kapoor SG (2005) On the modeling and analysis of machining performance in micro-endmilling, part I: surface generation. ASME. J Manuf Sci Eng 126(4):685–694
Woon KS, Rahman M, Fang FZ, Neo KS, Liu K (2008) Investigations of tool edge radius effect in micromachining: a FEM simulation approach. J Mater Process Technol 195:204–211
Wang J, Gong Y, Abba G, Antoine JF, Shi J (2009) Chip formation analysis in micromilling operation. Int J Adv Manuf Technol 45:430–447
Lai X, Li H, Li C, Lin Z, Ni J (2008) Modelling and analysis of micro scale milling considering size effect, micro cutter edge radius and minimum chip thickness. Int J Mach Tools Manuf 48:1–14
SrinivasRao U, Vijayaraghavan L (2013) Determination of minimum uncut chip thickness in mechanical micro-machining using Johnson-Cook fracture model. International Journal of Mechatronics and Manuf Syst 6(4):367–380
Ducobu F, Rivière-Lorphèvre E, Filippi E (2017) Experimental and numerical investigation of the uncut chip thickness reduction in Ti6Al4V orthogonal cutting. Meccanica 52(7):1577–1592
Shi Z, Li Y, Liu Z, Qiao Y (2017) Determination of minimum uncut chip thickness during micro-end milling Inconel 718 with acoustic emission signals and FEM simulation. Int J Adv Manuf Technol:1–9
Oliaei SNB, Karpat Y (2017) Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge. Int J Adv Manuf Technol 90:819–829
Shao F, Liu Z, Wan Y, Shi Z (2010) Finite element simulation of machining of Ti-6Al-4V alloy with thermodynamical constitutive equation. Int J Adv Manuf Technol 49:431–439
Danish M, Ginta TL, Habib K, Carou D, Rani AMA, Saha BB (2017) Thermal analysis during turning of AZ31 magnesium alloy under dry and cryogenic conditions. Int J Adv Manuf Technol 91:2855–2868
Mamedov A, Lazoglu I (2016) Thermal analysis of micro milling titanium alloy Ti–6Al–4V. J Mater Process Technol 229:659–667
Zhanqiang L, Zhenyu S, Yi W (2013) Definition and determination of the minimum uncut chip thickness of microcutting. Int J Adv Manuf Technol 69:1219–1232
Karpat Y, Ozel T (2008) Processing simulations for 3D turning using uniform and variable microgeometry PCBN tools. Int J Machi 4(1):26–38
Guo YB, Anurag S (2009) A novel hybrid predictive model and validation of unique hook-shaped residual stress profiles in hard turning. CIRPAnn Manuf Technol 58:81–84
Weule H, Huntrup V, Tritschler H (2001) Micro-cutting of steel to meet new requirements in miniaturization. CIRP Ann Manuf Technol 50(1):61–64
Filiz S, Conley CM, Wasserman MB, Ozdoganlar OB (2007) An experimental investigation of micro-machinability of copper 101 using tungsten carbide micro-endmills. Int J Mach Tools Manuf 47:1088–1100
Kang I S, Kim J S, Seo Y W (2011) Investigation of cutting force behaviour considering the effect of cutting edge radius in the micro-scale milling of AISI 1045 steel. Proc Inst Mech Eng. Part B: J Eng Manuf 225:163–171
de Oliveira FB, Roger Rodrigues A, Teixeira Coelho R, Fagalide Souza A (2015) Size effect and minimum chip thickness in micromilling. Int J Mach Tools Manuf 89:39–54
Wu X, Li L, Zhao M, He N (2016) Experimental investigation of specific cutting energy and surface quality based on negative effective rake angle in micro turning. Int J Adv Manuf Technol 82:1941–1947
Kim C, Mayor J, Ni J (2005) A static model of chip formation in microscale milling. ASME. J Manuf Sci Eng 126(4):710–718
Oliaei SNB, Karpat Y (2016) Investigating the influence of built-up edge on forces and surface roughness in micro scale orthogonal machining of titanium alloy Ti6Al4V. J Mater Process Technol 235:28–40
Jun MB, DeVor RE, Kapoor SG (2006) Investigation of the dynamics of microend milling—part II: model validation and interpretation. J Manuf Sci Eng 128(4):901–912
Cuba Ramos A, Autenrieth H, Strauß T, Deuchert M, Hoffmeister J, Schulze V (2012) Characterization of the transition from ploughing to cutting in micro machining and evaluation of the minimum thickness of cut. J Mater Process Technol 212:594–600
Mian AJ, Driver N, Mativenga PT (2011) Estimation of minimum chip thickness in micro-milling using acoustic emission. Proc IMechE Part B: J Eng Manuf 225(9):1535–1551
Zheng X, Liu Z, Chen M (2013) Experimental study on micro-milling of Ti6Al4V with minimum quantity lubrication. Int J Nanomanuf 9:570–582
Cheng K, Huo D (eds) (2013) Micro cutting: fundamentals and applications. John Wiley & Sons, Chichester
Budak E, Ozlu E, Bakioglu H, Barzegar Z (2016) Thermo-mechanical modeling of the third deformation zone in machining for prediction of cutting forces. CIRP Annals-Manufacturing Technology 65(1):121–124
Lui K, Melkote SN (2007) Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process. Int J Mech Sci 49:650–660
Singaravel B, Selvaraj T (2016) Experimental investigation on cutting forces, specific cutting pressure, co-efficient of friction and shear energy in turning of HSLA steel. Manag Prod Eng Rev 7(1):71–76
Malkin S (2008) Grinding technology: theory and applications of machining with abrasives, second edn. Industrial Press, New York
Aramcharoen A, Mativenga PT (2009) Size effect and tool geometry in micromilling of tool steel. Precis Eng 33(4):402–407
Acknowledgements
The authors would like to acknowledge the South Pars Gas Complex (SPGC) of Iran and the Machining Research Laboratory (MRL) of Sabanci University for the financial support. The authors would also like to thank Suleyman Tutkun and Veli Naksiler for technical assistance.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Rezaei, H., Sadeghi, M.H. & Budak, E. Determination of minimum uncut chip thickness under various machining conditions during micro-milling of Ti-6Al-4V. Int J Adv Manuf Technol 95, 1617–1634 (2018). https://doi.org/10.1007/s00170-017-1329-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-1329-3