Theoretical and Experimental Study on Dynamic Minimum Cutting Thickness
DOI:
https://doi.org/10.37255/jme.v21i3pp117-128Keywords:
Dynamic minimum cutting thickness;Abstract
The cutting thickness has a significant impact on surface quality: the thinner the cutting thickness, the easier it is to achieve good surface quality. The minimum cutting thickness represents the limit for chip formation. Theoretically, performing ultra-precision cutting at the minimum cutting thickness enables the achievement of an excellent machined surface with minimal surface damage and exceptional surface quality. Therefore, exploring the formation mechanism of the minimum cutting thickness and investigating the formation mechanism of surface micro topography under extreme cutting conditions are of great significance for further clarifying the extreme cutting theory, improving surface quality, and extending tool life. A dynamic minimum cutting thickness theory is proposed, followed by calculations and simulations. Furthermore, scratch experiments on aluminum alloys and red copper are conducted using a single-crystal diamond tool, during which the cutting force and scratch depth are measured. The minimum cutting thickness of aluminum alloys and red copper is determined by leveraging the corresponding relationship between the abrupt change in cutting force (from the plowing stage to the cutting stage) and the scratch depth. Based on the minimum cutting thickness, the optimal cutting parameters for the non-free cutting of aluminum alloys and red copper were obtained, and non-free cutting experiments were conducted using these parameters. The results show that the minimum cutting thickness of aluminum alloys and red copper increases with increasing feed rate. The ratios of the minimum cutting thickness to the tool edge radius are in the ranges of 0.243–0.271 and 0.20–0.36, respectively. The optimal surface roughness values are as follows: Rz = 1.505 μm and 2.014 μm, and Ra = 0.293 μm and 0.309 μm, respectively
Downloads
References
[1]. Ikawa, N., Shimada, S., and Tanaka, H., “Minimum thickness of cut in micromachining,” Nanotechnology, vol. 3, no. 1, pp. 6–9, 1992.
[2]. Shimada, S., Ikawa, N., Tanaka, H., et al., “Feasibility study on ultimate accuracy in microcutting using molecular dynamics simulation,” CIRP Annals, vol. 42, no. 1, pp. 91–94, 1993.
[3]. Yuan, Z. J., Zhou, M., and Dong, S., “Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining,” Journal of Materials Processing Technology, vol. 62, no. 4, pp. 327–330, 1996.
[4]. Son, S. M., Lim, H. S., and Ahn, J. H., “Effects of the friction coefficient on the minimum cutting thickness in micro cutting,” International Journal of Machine Tools and Manufacture, vol. 45, nos. 4–5, pp. 529–535, 2005.
[5]. Zhang, H. L., Kuai, J. C., and Zhang, F. H., “Minimum thickness of cut in nanomachining using atomic force microscopy,” in Proc. 2010 Int. Conf. E-Product E-Service and E-Entertainment (ICEEE), IEEE Conference Publishing, pp. 1276–1279, 2010.
[6]. Zhi, C. N., Fei, F. J., and Kai, C., “An innovative investigation on chip formation mechanisms in micro-milling using natural diamond and tungsten carbide tools,” Journal of Manufacturing Processes, vol. 31, pp. 382–394, 2018.
[7]. Xian, W., Li, L., Ming, Y. D., Jian, Y. S., Feng, J., Yuan, L., and Yi, Y. L., “Experimental study on the minimum undeformed chip thickness based on effective rake angle in micro milling,” Micromachines, vol. 11, p. 924, 2020.
[8]. Zhenyu, S., Yu, C. L., Zhan, Q. L., and Yang, Q., “Determination of minimum uncut chip thickness during micro-end milling Inconel 718 with acoustic emission signals and FEM simulation,” International Journal of Advanced Manufacturing Technology, vol. 98, pp. 37–45, 2018.
[9]. Wojciechowski, S., “Estimation of minimum uncut chip thickness during precision and micro-machining processes of various materials—A critical review,” Materials, vol. 15, p. 59, 2022, doi: 10.3390/ma15010059.
[10]. Lane, B. M., Dow, T. A., and Scattergood, R., “Thermo-chemical wear model and worn tool shapes for single-crystal diamond tools cutting steel,” Wear, vol. 300, pp. 216–224, 2013.
[11]. Shi, Q. L., Hai, J. Z., Liang, Z., et al., “Coupled thermo-mechanical sticking-sliding friction model along tool-chip interface in diamond cutting of copper,” Journal of Manufacturing Processes, vol. 70, pp. 578–592, 2021.
[12]. Wan, Q. C., De, H. H., Xiang, Y. T., et al., “Surface generation modelling for micro end milling considering the minimum chip thickness and tool runout,” Procedia CIRP, vol. 58, pp. 364–369, 2017.
[13]. Grzesik, W., “A revised model for predicting surface roughness in turning,” Wear, vol. 194, no. 1, pp. 143–148, 1996.
[14]. Liu, X., Devor, R. E., and Kapoor, S. G., “An analytical model for the prediction of minimum chip thickness in micromachining,” Journal of Manufacturing Science and Engineering, vol. 128, no. 2, pp. 474–481, 2006.
[15]. Özel, T., Liu, X., and Dhanorker, A., “Modelling and simulation of micro-milling process,” in Proc. 4th Int. Conf. and Exhibition on Design and Production of Machines and Dies/Molds, Cesme, Turkey, Jun. 21–23, 2007.
[16]. Malekian, M., Mostofa, M. G., Park, S., and Jun, M. B. G., “Modeling of minimum uncut chip thickness in micro machining of aluminum,” Journal of Materials Processing Technology, vol. 212, pp. 553–559, 2012.
[17]. Cuba Ramos, H., Autenrieth, T., Strauß, M., Deuchert, J., Hoffmeister, V., and Schulze, V., “Characterization of the transition from ploughing to cutting in micro machining and evaluation of the minimum thickness of cut,” Journal of Materials Processing Technology, vol. 212, pp. 594–600, 2012.
[18]. Przestacki, D., Chwalczuk, T., and Wojciechowski, S., “The study on minimum uncut chip thickness and cutting forces during laser-assisted turning of WC/NiCr clad layers,” International Journal of Advanced Manufacturing Technology, vol. 91, pp. 3887–3898, 2017.
[19]. Rezaei, H., Sadeghi, M. H., and Budak, E., “Determination of minimum uncut chip thickness under various machining conditions during micro-milling of Ti-6Al-4V,” International Journal of Advanced Manufacturing Technology, vol. 95, pp. 1617–1634, 2018.
[20]. Yip, W. S. and To, S., “Reduction of minimum cutting thickness of titanium alloys in micro cutting by a magnetic field assistance,” IEEE Access, vol. 7, pp. 152034–152041, 2019.
[21]. Mikołajczyk, T., Latos, H., Pimenov, D. Y., et al., “Influence of the main cutting edge angle value on minimum uncut chip thickness during turning of C45 steel,” Journal of Manufacturing Processes, vol. 57, pp. 354–362, 2020, doi: 10.1016/j.jmapro.2020.06.040.
[22]. Mikołajczyk, T., Latos, H., Szczepaniak, Z., et al., “Theoretical and experimental research of edge inclination angle effect on minimum uncut chip thickness in oblique cutting of C45 steel,” International Journal of Advanced Manufacturing Technology, vol. 124, nos. 7–8, pp. 2299–2312, 2023.
[23]. Yi, Q. L., Zhan, J. Y., Jin, K. X., Xiao, Z. L., and Hua, D. Y., “An analytical model for micro-cutting considering the cutting tool edge radius effect and material separation,” International Journal of Advanced Manufacturing Technology, vol. 114, pp. 97–105, 2021.
[24]. Zhe, J. Y. and Xian, K. W., Precision and Ultraprecision Machining Technology. Beijing, China: China Machine Press, 2016.
[25]. Zhan, Q. L., Zhen, Y. S., and Yi, W., “Definition and determination of the minimum uncut chip thickness of microcutting,” International Journal of Advanced Manufacturing Technology, vol. 69, nos. 5–8, pp. 1219–1232, 2013, doi: 10.1007/s00170-013-5109
