Effects of Ploughing Forces and Friction Coefficient in Microscale Machining

[+] Author and Article Information
Siva Venkatachalam

The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, 813 Ferst Drive, N.W., Atlanta, GA 30332siva.venkatachalam@gatech.edu

Steven Y. Liang

The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, 813 Ferst Drive, N.W., Atlanta, GA 30332steven.liang@me.gatech.edu

J. Manuf. Sci. Eng 129(2), 274-280 (Sep 20, 2006) (7 pages) doi:10.1115/1.2673449 History: Received March 13, 2006; Revised September 20, 2006

This paper discusses the effects of ploughing and friction in microscale machining. The friction coefficient has previously been shown to be sensitive to the geometry of the abrasive particle and the depth of indentation. From a micromachining standpoint, the friction coefficient is modeled to be a function of the tool edge radius and the undeformed chip thickness, wherein the tool edge is modeled as a sliding cylinder on a flat workpiece. The contributions of ploughing force, which assumes significance in microscale machining, are better modeled using an integration approach over the edge of the tool. Two force models for the estimation of ploughing forces are compared, wherein one model uses a slip-line field analysis and the other uses a method of force balance on the deformation boundary. Basic microcutting (shaping) experimental data are presented and compared to the prediction results. The results show that a nonuniform friction coefficient improves the predictability of the force model.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Stresses along the tool assuming a power-law distribution (Ref. 14)

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Figure 2

(a) Representation of cutting edge and (b) flow pattern of workpiece material approaching a tool (Ref. 8)

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Figure 3

Schematic of the mechanics around the rounded edge of the tool (Ref. 13)

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Figure 4

Variation of the friction coefficient with the ratio of depth of indentation to the tool tip radius (Ref. 20)

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Figure 5

Spherical asperity sliding on softer workpiece material

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Figure 6

Schematic of the tool ploughing the workpiece

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Figure 7

(a) Measurement of tool-edge radius and (b) progression of tool wear

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Figure 8

Sample chip thickness and width for an undeformed chip thickness of 3μm

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Figure 9

Cutting and thrust force experimental data

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Figure 10

Ploughing force comparison between Endres and Waldrof models (Refs. 9,11)

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Figure 11

Coefficient of ploughing friction

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Figure 12

Comparison on experimental and predicted cutting force results

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Figure 13

Variation of cutting force with varying tool-edge radii



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