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TECHNICAL PAPERS

The Mechanics of Machining at the Microscale: Assessment of the Current State of the Science

[+] Author and Article Information
X. Liu, R. E. DeVor, S. G. Kapoor

Department of Mechanical and Industrial Engineering University of Illinois at Urbana-Champaign, Urbana, IL

K. F. Ehmann

Department of Mechanical Engineering, Northwestern University, Evanston, IL

J. Manuf. Sci. Eng. 126(4), 666-678 (Feb 04, 2005) (13 pages) doi:10.1115/1.1813469 History: Received August 18, 2004; Revised September 02, 2004; Online February 04, 2005
Copyright © 2004 by ASME
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References

Figures

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(a) Micromilled trenches with stepped walls 8, (b) neurovascular device component, and (c) microgear
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Direction of resultant force vector for new and worn tools with the same overall tool geometry 20
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Effect of tool edge condition on thrust force in orthogonal flycutting of Al 6061-T6 21
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Chips generated at an uncut chip thickness of 1 nm 23
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Theoretical surface profile considering the minimum chip thickness effect 17
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Experimental Y force (normal to the feed force) and the corresponding power spectrum 14
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Effect of tool edge radius on surface roughness for pearlite 25
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Burr formation in micromilling: (a) flag-type burr on tool exit and (b) rollover-type burr on tool entrance 27
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SEM photographs of machined silicon wafer surfaces for different maximum undeformed chip thickness (dmax) and tool edge radius values 37
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Cross section profile of scratch groove 44
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The effects of the crystallographic orientation and the depth of cut on the surface roughness 48
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Experimental cutting forces in micromilling of pearlitic ductile iron 18
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SEM image of (a) ferrite slot floor, (b) ferritic ductile iron slot floor, (c) fearltie chips, and (d) ferritic ductile iron chips 25
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Schematic of the model used in the MD simulation of nanometric cutting of single-crystal aluminum 56
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Three modes of dislocation motion 56
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Material flow near a rounded cutting edge 57
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Effective stress contours 60
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Variation of specific cutting energy with undeformed chip thickness 60
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Endmilling of ductile iron workpiece 18
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Effect of minimum chip thickness on surface roughness 25
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Tool vibration histories and frequency spectra for machining pearlite at different feed rate 71
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Chipload/force relationship for pearlite 71

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