Research Papers

Experimental Evaluation and Modeling Analysis of Micromilling of Hardened H13 Tool Steels

[+] Author and Article Information
Hongtao Ding, Ninggang Shen

Professor ASME FellowCenter for Laser-based Manufacturing, School of Mechanical Engineering,  Purdue University, West Lafayette, IN 47907

Yung C. Shin1

Professor ASME Fellowshin@purdue.eduCenter for Laser-based Manufacturing, School of Mechanical Engineering,  Purdue University, West Lafayette, IN 47907shin@purdue.edu


Corresponding author.

J. Manuf. Sci. Eng 133(4), 041007 (Jul 27, 2011) (11 pages) doi:10.1115/1.4004499 History: Received March 07, 2011; Revised June 24, 2011; Published July 27, 2011; Online July 27, 2011

This study is focused on experimental evaluation and numerical modeling of micromilling of hardened H13 tool steels. Multiple tool wear tests are performed in a microside cutting condition with 100 μm diameter endmills. The machined surface integrity, part dimension control, size effect, and tool wear progression in micromachining of hardened tool steels are experimentally investigated. A strain gradient plasticity model is developed for micromachining of hardened H13 tool steel. Novel 2D finite element (FE) models are developed in software ABAQUS to simulate the continuous chip formation with varying chip thickness in complete micromilling cycles under two configurations: microslotting and microside cutting. The steady-state cutting temperature is investigated by a heat transfer analysis of multi micromilling cycles. The FE model with the material strain gradient plasticity is validated by comparing the model predictions of the specific cutting forces with the measured data. The FE model results are discussed in chip formation, stress, temperature, and velocity fields to great details. It is shown that the developed FE model is capable of modeling a continuous chip formation in a complete micromilling cycle, including the size effect. It is also shown that the built-up edge in micromachining can be predicted with the FE model.

Copyright © 2011 by American Society of Mechanical Engineers
Topics: Cutting , Stress , Wear , Force
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Figure 1

Chip formation relative to chip load and cutting edge radius

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Figure 2

Micromilling experimental configurations

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Figure 3

Geometry and dimensions of 100 μm diameter endmill. (a) SEM micrograph (b) Tool dimension in μm: radial rake angle, a = 12 deg; radial relief angle, b = 30 deg; helix angle, c = 35 deg; Width of land, wol = 40 μm (c) 3D overview

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Figure 4

Schematic of tool path in side cutting

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Figure 5

AE RMS signals recorded during the 20th pass side cutting

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Figure 6

Average AE RMS signals recorded over multiple-pass in side cutting

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Figure 7

Machined slot geometry produced after about 3 min side cutting (15 passes)

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Figure 8

Typical 3D surface profile produced by side cutting

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Figure 9

Micrographs of machined surface generated by side cutting

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Figure 10

Close look of SEM image of surface defects on the machined surface after 6-min side cutting

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Figure 11

Tool wear measurements for a tool after 6-min side cutting

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Figure 12

Tool wear progress in side cutting for tool 1

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Figure 13

Tool edge radius and maximum flank wear progress in side cutting

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Figure 14

FE model setups

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Figure 15

Workpiece temperature field during the 16th microslotting cycle of condition A

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Figure 16

Workpiece nodal temperature histories of multiple milling cycles

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Figure 17

Comparison between measured and predicted (with and without strain gradient plasticity) specific cutting forces in micromilling of hardened H13 steel of 45 HRC

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Figure 18

Chip formation and von Mises stress distributions during one side cutting cycle with a 0.5 μm edge radius endmill

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Figure 19

Deformation fields during side cutting with different tool edge radii



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