Investigation of cutting force behaviour considering the effect of cutting edge radius in the micro-scale milling of AISI 1045 steel

Abstract

This paper presents the cutting force behaviour resulting from the effect of cutting edge radius in the micro-scale milling of AISI 1045 steel using tungsten carbide tools. The cutting edge radius of the micro-milling tool is on the order of a few microns or submicrons; hence, the uncut chip thickness reaches the scale of cutting edge radius. Owing to the scaling effect, the cutting force behaviour is different from that in conventional-scale milling. Experiments are conducted with half-immersion milling that uses micro-milling tools. The feed- and normal-direction cutting forces are decomposed into the principal- and thrust-direction cutting forces. The cutting forces are analysed to investigate the effect of cutting edge radius. The minimum uncut chip thickness can be obtained by investigating the cutting force behaviour. Also, the characteristics of specific energies due to the size effect are evaluated for the micro-scale milling process.

Size effect and minimum chip thickness in micromilling

“…By considering the same workpiece material, the results of minimum uncut chip thickness found in this paper match those of Cuba Ramos et al [10], Kang et al [12], Liu et al [8] and Vogler et al [6], even when using different analyzed variables and techniques for measuring or estimating h min .…”

“…Kang et al [12] found a similar behaviour of the specific cutting force presented in Fig. 14 when micromilling AISI 1045 steel with a two fluted WC endmill coated with TiNAl (equal to the current).…”

“…Micromilling experimental tests confirmed the size effect given that the specific cutting force was lower than 20 GPa for f4 h min and close to 40 GPa for f oh min . Kang et al [12] assert that minimum uncut chip thickness is 30% of the tool edge radius when micromilling AISI 1045 steel. Their finding is based on constant cutting force whenever hoh min .…”

Investigation on Innovative Dynamic Cutting Force Modelling in Micro-milling and Its Experimental Validation

“…Matsumura and Tamura [21] developed an analytical model to evaluate the effect of the cutter run-out on the cutting force in order to perform the milling operation properly. In addition, the experimental results from Kang et al [22] presented that the effect of cutting edge radius on cutting forces was significant in the micro-scale milling. However, the modelling approaches and techniques developed so far are almost all focused on obtaining the absolute value of cutting forces.…”

Simulation and Analysis on Micro Milling of AISI 1045

“…Kang et al [8] investigated the cutting force behavior associated with the effect of cutting edge radius in the micro-scale milling of AISI 1045 steel.…”