Modelling of the Combined Microstructural and Cutting Edge Effects in Ultraprecision Machining

Document Type

Article

Publication Date

4-21-2018

Publication Title

CIRP Annals - Manufacturing Technology

Abstract

The mechanics of ultraprecision machining (UPM) is known to be affected by materials microstructures and cutting tool geometries when cutting magnitudes are reduced to micron-scale. To model the combined effects, a flow stress model that correlates the grain size and chip thickness to the relative tool sharpness is first proposed. Subsequently a novel behavioural chip formation model is developed to distinguish the transitions in chip formation regimes due to the microstructural and cutting edge effects. This led to the discovery of a unique finishing regime where surface roughness is improved by 61.7%, 63.9% and 86.4% for Al-alloy, Mg-alloy and Cu-alloy respectively.

Keywords

Cutting edge; Finishing; Micro structure; Aluminum alloys; Copper alloys; Chip formations; Chip thickness; Combined effect; Cutting tool geometry; Flow stress models; Micro-structural; Ultraprecision machining

Disciplines

Mechanical Engineering

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