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TECHNICAL PAPERS

An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining

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

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, 1206 W. Green Street, Urbana, IL 61801

J. Manuf. Sci. Eng 128(2), 474-481 (Sep 20, 2005) (8 pages) doi:10.1115/1.2162905 History: Received May 26, 2005; Revised September 20, 2005

In micromachining, the uncut chip thickness is comparable or even less than the tool edge radius and as a result a chip will not be generated if the uncut chip thickness is less than a critical value, viz., the minimum chip thickness. The minimum chip thickness effect significantly affects machining process performance in terms of cutting forces, tool wear, surface integrity, process stability, etc. In this paper, an analytical model has been developed to predict the minimum chip thickness values, which are critical for the process model development and process planning and optimization. The model accounts for the effects of thermal softening and strain hardening on the minimum chip thickness. The influence of cutting velocity and tool edge radius on the minimum chip thickness has been taken into account. The model has been experimentally validated with 1040 steel and Al6082-T6 over a range of cutting velocities and tool edge radii. The developed model has then been applied to investigate the effects of cutting velocity and edge radius on the normalized minimum chip thickness for various carbon steels with different carbon contents and Al6082-T6.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 1

Slip-line field model and the associated velocity hodograph (see Ref. 14)

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Figure 2

SEM image of the round cutting edge

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Figure 4

SEM image of the sidewall surface

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Figure 5

Extraction of the minimum chip thickness tcmin from the surface profile measured by Wyko optical profiler

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Figure 6

Values of σ1 obtained from high speed compression tests (see Ref. 19)

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Figure 7

Values of n1 obtained from high speed compression tests (see Ref. 19)

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Figure 8

Experimental and predicted normalized minimum chip thickness (λn) for 1040 steel

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Figure 9

Experimental and predicted normalized minimum chip thickness (λn) for Al6082-T6

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Figure 10

Effect of cutting velocity on normalized minimum chip thickness

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Figure 11

Effect of edge radius on the minimum chip thickness to edge radius ratio

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Figure 12

Normalized minimum chip thickness (λn) for 1018 steel and 1040 steel

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Figure 13

Normalized minimum chip thickness (λn) for Al6082-T6

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Figure 3

Illustration of the sidewall surface generation taking into account the minimum chip thickness effect

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