0
Research Papers

Finite Element-Based Study of the Mechanics of Microgroove Cutting

[+] Author and Article Information
Keith A. Bourne

e-mail: kbourne200@gmail.com

Shiv G. Kapoor

Grayce Wicall Gauthier Chair in Mechanical Science and Engineering
e-mail: sgkapoor@illinois.edu

Richard E. DeVor

College of Engineering Distinguished
Professor of Manufacturing
Department of Mechanical Science and Engineering
University of Illinois at Urbana-Champaign,
Urbana, IL 61801

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received May 18, 2011; final manuscript received February 11, 2013; published online May 27, 2013. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 135(3), 031017 (May 27, 2013) (8 pages) Paper No: MANU-11-1182; doi: 10.1115/1.4024154 History: Received May 18, 2011; Revised February 11, 2013

In an earlier paper, a high-speed microgroove cutting process that makes use of a flexible single-point cutting tool was presented. In this paper, 3D finite element modeling of this cutting process is used to better understand process mechanics. The development of the model, including parameter estimation and validation, is described. Validation experiments show that on average the model predicts side burr height to within 2.8%, chip curl radius to within 4.1%, and chip thickness to within 25.4%. The model is used to examine chip formation, side burr formation, and exit burr formation. Side burr formation is shown to primarily occur ahead of a tool and is caused by expansion of material compressed after starting to flow around a tool rather than becoming part of a chip. Exit burr formation is shown to occur when a thin membrane of material forms ahead of a tool and splits into two side segments and one bottom segment as the tool exits a workpiece.

FIGURES IN THIS ARTICLE
<>
Copyright © 2013 by ASME
Your Session has timed out. Please sign back in to continue.

References

Bourne, K. A., Kapoor, S. G., and DeVor, R. E., 2010, “Machining Micro-Scale Grooves Using a Flexible Single-Point Cutting Tool,” Proceedings of the 5th International Conference of MicroManufacturing, Paper No. 1857.
Zhu, P., Hu, Y., Ma, T., and Wang, H., 2010, “Study of AFM-Based Nanometric Cutting Process Using Molecular Dynamics,” Appl. Surf. Sci., 256, pp. 7160–7165. [CrossRef]
Marusich, T. D., 2001, “Effects of Friction and Cutting Speed on Cutting Force,” Proceedings of IMECE, Paper No. MED-23313, pp. 1–9.
Kopalinsky, E. M., and Oxley, P. L. B., 1984, “Size Effects in Metal Removal Processes,” Proceedings of the 3rd Conference on Mechanical Properties of Materials at High Rates of Strain, pp. 389–396.
Oxley, P. L. B., 1989, Mechanics of Machining: An Analytical Approach to Assessing Machinability, Ellis Horwood Ltd., Chichester, UK.
Liu, K., and Melkote, S. N., 2006, “Material Strengthening Mechanisms and Their Contribution of Size Effect in Micro-Cutting,” ASME J. Manuf. Sci. Eng., 128(3), pp. 730–738. [CrossRef]
Liu, X., DeVor, R. E., and Kapoor, S. G., 2006, “An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining,” ASME J. Manuf. Sci. Eng., 128(2), pp. 474–481. [CrossRef]
Dassault Systèmes Simulia Corp., 2009, “abaqus 6.9 Analysis User's Manual.”
Zorev, N. N., 1963, “Interrelationship Between Shear Processes Occurring Along Tool Face and on Shear Plane in Metal Cutting,” International Production Engineering Research Conference, pp. 42–49.
Kota, N., and Ozdoganlar, B., 2010, “Machining Force and Surface Finish Variation Across Grains During Orthogonal Micromachining of Aluminum,” 5th International Conference on Micromanufacturing, pp. 133–137.
Subbiah, S., and Melkote, S. N., 2007, “Evidence of Ductile Tearing Ahead of the Cutting Tool and Modeling the Energy Consumed in Material Separation in Micro-Cutting,” ASME J. Eng. Mater. Technol., 129(2), pp. 321–331. [CrossRef]
Akarca, S. S., Song, X., Altenhof, W. J., and Alpas, A. T., 2008, “Deformation Behavior of Aluminum During Machining: Modeling by Eulerian and Smoothed-Particle Hydrodynamics Methods,” Proc. Inst. Mech. Eng., Part L, 222, pp. 209–221.
Brantley, W. A., 1973, “Calculated Elastic Constants for Stress Problems Associated With Semiconductor Devices,” J. Appl. Phys., 44(1), pp. 534–535. [CrossRef]
Lindholm, U. S., 1964, “Some Experiments With the Split Hopkinson Pressure Bar,” J. Phys. Solids, 12, pp. 317–335. [CrossRef]
Robertson, K. D., Chou, S.-C., and Rainey, J. H., 1971, “Design and Operating Characteristics of a Split Hopkinson Pressure Bar Apparatus,” Defense Technical Information Center, Technical Report No. AD0741371.
Khan, A. S., and Huang, S., 1992, “Experimental and Theoretical Study of Mechanical Behavior of 1100 Aluminum in the Strain Rate Range 105–104 s1,” Int. J. Plast., 8, pp. 397–424. [CrossRef]
Frantz, R. A., and Duffy, J., 1972, “The Dynamic Stress-Strain Behavior in Torsion of 1100-O Aluminum Subjected to a Sharp Increase in Strain Rate,” ASME J. Appl. Mech., 39(4), pp. 939–945. [CrossRef]
Kloop, R. W, Clifton, R. J., and Shawki, T. G., 1985, “Pressure-Shear Impact and the Dynamic Viscoplastic Response of Metals,” Mech. Mater., 4, pp. 375–385. [CrossRef]
Johnson, G. R., and Cook, W. H., 1985, “Fracture Characteristics of Three Metals Subjected to Various Strains, Strain Rate, Temperatures and Pressures,” Eng. Fract. Mech., 21(1), pp. 31–48. [CrossRef]
Gupta, N. K., Iqbal, M. A., and Sekhon, G. S., 2006, “Experimental and Numerical Studies on the Behavior of Thin Aluminum Plates Subjected to Impact by Blunt- and Hemispherical-Nosed Projectiles,” Int. J. Impact Eng., 32, pp. 1921–1944. [CrossRef]
Kay, G., 2003, “Failure Modeling of Titanium 6Al-4V and Aluminum 2024-T3 With the Johnson-Cook Material Model,” U.S. Department of Transportation Federal Aviation Administration, Paper No. DOT/FAA/AE-03/57.
Park, I. W., and Dornfeld, D. A., 2000, “A Study of Burr Formation Processes Using the Finite Element Method: Part I,” ASME J. Eng. Mater. Technol., 122(2), pp. 221–228. [CrossRef]
Gillespie, L. K., 1999, Deburring and Edge Finishing Handbook, ASME Press, New York.

Figures

Grahic Jump Location
Fig. 1

Side burrs on side of groove cross-section

Grahic Jump Location
Fig. 2

Exit burrs at groove intersections

Grahic Jump Location
Fig. 5

Overall model geometry

Grahic Jump Location
Fig. 6

Simulated tool (a) and gap under tool (b)

Grahic Jump Location
Fig. 7

Material failure regions

Grahic Jump Location
Fig. 8

Material shear strength at rake face

Grahic Jump Location
Fig. 9

Symmetry plane stress (left) and strain (right)

Grahic Jump Location
Fig. 10

Surface and subsurface stresses and strains

Grahic Jump Location
Fig. 11

Flow of material around tool

Grahic Jump Location
Fig. 12

Side burr formation events

Grahic Jump Location
Fig. 13

Exit burr formation events

Tables

Errata

Discussions

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