A Static Model of Chip Formation in Microscale Milling

[+] Author and Article Information
Chang-Ju Kim, J. Rhett Mayor, Jun Ni

S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

J. Manuf. Sci. Eng 126(4), 710-718 (Feb 04, 2005) (9 pages) doi:10.1115/1.1813475 History: Received February 17, 2004; Revised July 22, 2004; Online February 04, 2005
Copyright © 2004 by ASME
Your Session has timed out. Please sign back in to continue.


Kussul,  E. M., Rachkovskij,  D. A., Baidyk,  T. N., and Talayev,  S. A., 1996, “Micromechanical Engineering: A Basis for the Low-Cost Manufacturing of Mechanical Microdevices Using Microequipment,” J. Micromech. Microeng., 6, pp. 410–425.
Masuzawa,  T., and Tonshoff,  H. K., 1997, “Three-Dimensional Micromachining by Machine Tools,” CIRP Ann., 46, pp. 621–628.
Vasile,  M. J., Friedrich,  C. R., Kikkeri,  B., and Mcelhannon,  R., 1996, “Micrometer-Scale Machining: Tool Fabrication and Initial Results,” Precision Eng.,19, pp. 180–186.
Weck,  M., Fischer,  S., and Vos,  M., 1997, “Fabrication of Microcomponents Using Ultraprecision Machine Tools,” Nanotechnology, 8, pp. 145–148.
Friedrich,  C., Coane,  P., Goettert,  J., and Gopinathin,  N., 1998, “Direct Fabrication of Deep X-Ray Lithography Masks by Micromechanical Milling,” Precision Eng.,22, pp. 164–173.
Schaller,  T., Bohn,  L., Mayer,  J., and Schubert,  K., 1999, “Microstructure Grooves With a Width of Less Than 50 Micrometer Cut With Ground Hard Metal Micro End Mills,” Precision Eng.,23, pp. 229–235.
Weule,  H., Huntrup,  V., and Tritschle,  H., 2001, “Micro-Cutting of Steel to Meet New Requirements in Miniaturization,” CIRP Ann., 50, pp. 61–64.
Chuzhoy,  L., Devor,  R. E., Kapoor,  S. G., Beaudoin,  A. J., and Bammann,  D. J., 2003, “Machining Simulation of Ductile Iron and Its Constituents, Part 1: Estimation of Material Model Parameters and Their Validation,” ASME J. Manuf. Sci. Eng., 125, pp. 181–191.
Chuzhoy,  L., and Devor,  R. E., 2003, “Machining Simulation of Ductile Iron and Its Constituents, Part 2: Numerical Simulation and Experimental Validation of Machining,” ASME J. Manuf. Sci. Eng., 125, pp. 192–201.
Vogler,  M. P., Devor,  R. E., and Kapoor,  S. G., 2003, “Microstructure-Level Force Prediction Model for Micro-Milling of Multi-Phase Materials,” ASME J. Manuf. Sci. Eng., 125, pp. 202–209.
Kim,  C.-J., Bono,  M., and Ni,  J., 2002, “Experimental Analysis of Chip Formation in Micro-Milling,” Trans. NAMRI/SME,30, pp. 247–254.
Martellotti,  M. E., 1941, “An Analysis of the Milling Process,” Trans. ASME, 63, pp. 677–700.
Komanduri,  R., 1971, “Some Aspects of Machining With Negative Rake Tools Simulating Grinding,” Int. J. MTDR,11, pp. 223–233.
Abdelmoneim,  M. E., and Scrutton,  R. F., 1973, “Post-Machining Plastic Recovery and the Law of Abrasive Wear,” Wear, 24, pp. 1–13.
Basuray,  P. K., Misra,  B. K., and Lal,  G. K., 1977, “Transition From Ploughing to Cutting During Machining With Blunt Tools,” Wear, 43, pp. 341–349.
Yuan,  Z. J., Zhou,  M., and Dong,  S., 1996, “Effect of Diamond Tool Sharpness on Minimum Cutting Thickness and Cutting Surface Integrity in Ultraprecision Machining,” J. Mater. Process. Technol., 62, pp. 327–330.
Merchant,  M. E., 1944, “Basic Mechanics of the Metal-Cutting Process,” ASME J. Appl. Mech., 12, pp. 168–175.
Nakayama, K., and Tamura, K., 1967, “Size Effect in Metal-Cutting Force,” ASME Papers, Vol. 67-PROD-9, pp. 1–8.
Abdelmoneim,  M. E., and Scrutton,  R. F., 1974, “Tool Edge Roundness and Stable Build-up Formation in Finish Machining,” ASME J. Eng. Ind., 96, Ser B, pp. 1258–1267.
Lucca,  D. A., and Seo,  Y. W., 1993, “Effect of Tool Edge Geometry on Energy Dissipation in Ultraprecision Machining,” CIRP Ann., 42, pp. 83–86.
Waldorf,  D. J., Devor,  R. E., and Kapoor,  S. G., 1998, “A Slip-Line Field for Ploughing During Orthogonal Cutting,” ASME J. Manuf. Sci. Eng., 120, pp. 693–699.
Torrence,  C., and Compo,  G. P., 1998, “A Practical Guide to Wavelet Analysis,” Bull. Am. Meteorol. Soc.,79, pp. 61–78.


Grahic Jump Location
Schematic of the milling process
Grahic Jump Location
Interaction between the cutting edge and the workpiece
Grahic Jump Location
Consecutive chip formation (h(θ0)>hm)
Grahic Jump Location
Intermittent chip formation (h(θ0)<hm)
Grahic Jump Location
Calculated variation of period as a function of position angle under an assumption of hm=3 μm
Grahic Jump Location
Measured and transformed cutting forces (Exp. I, ft=3 μm)
Grahic Jump Location
Cutting forces versus number of tooth passes (Exp. I, θ=90°)
Grahic Jump Location
Cutting forces versus number of tooth passes (Exp. II, θ=90 deg)
Grahic Jump Location
Cutting forces versus number of tooth passes (Exp. III, θ=90 deg)
Grahic Jump Location
Measured cutting forces as a function of the engagement
Grahic Jump Location
Graphs of the periodicity in force fluctuation with respect to n, which demonstrate that the period decreases with ft at any position angle
Grahic Jump Location
Feed per tooth and the minimum chip thickness




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In