Chip Morphology and Forces in End Milling of Elastomers

[+] Author and Article Information
Albert J. Shih, Jie Luo

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

Mark A. Lewis, John S. Strenkowski

Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27695-7910

J. Manuf. Sci. Eng 126(1), 124-130 (Mar 18, 2004) (7 pages) doi:10.1115/1.1633276 History: Received September 01, 2003; Online March 18, 2004
Copyright © 2004 by ASME
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Optical pictures of elastomer chip machined in Experiments I and III using tools #1 to #13
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The four-step procedure used to categorize chip morphology for an end milled elastomer
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Three end milling force components vs. time at the four corners of the test matrix in Experiment V: Tool 6, carbon dioxide cooled workpiece. [ ]: maximum uncut chip thickness in μm.
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Average peak milling forces vs. maximum uncut chip thickness in Experiment V at 2900 and 5500 rpm
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SEM micrographs of adiabatic shear band in the SFE type chip machined by Tool 8 in Experiment VII, 14.8 mm/s feed speed and 4200 rpm spindle speed, (a) overview of the chip and (b) close-up view shear band in the box in (a).
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SEM micrographs of (a) a curled, serrated SCE type chip with wavy marks machined by Tool 8 in Experiment III, (b) a SFE type of chip with the wavy serration mark on the surface.
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SEM micrographs of a RF type of chip machined by Tool 8 in Experiment I
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SEM micrographs of SCM type curled chip machined by Tool 11 in (a) Experiment I and (b) Experiment III
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(a) The RC and B types of chips machined by Tool 4 with 2.12 mm/s feed speed and 5500 rpm and (b) chip with burned edge, machined by Tool 2 in Experiment I
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SFM chip machined by Tool 4 at 5500 rpm and 14.8 mm/s feed speed
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Optical pictures of chip formation in the four corners of the test matrix in Experiment V, Tool 6 at (a) 2900 rpm, 2.12 mm/s feed, (b) 2900 rpm, 14.8 mm/s feed, (c) 5500 rpm, 2.12 mm/s feed, and (d) 5500 rpm, 14.8 mm/s feed. ( ): Cleanliness index of end milled groove.
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Definition of the directions of force components and general direction of the three force components generated by down-cut Tool 6 on the elastomer workpiece
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Three end milling force components vs. time for Tool 6 in Experiments I and III (4200 rpm and 12.7 mm/s feed speed)



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