Modeling and Simulation of Mechanical Micro-Machining—A Review

Anand, Ravi Shankar; Patra, Karali

doi:10.1080/10910344.2014.925377

Cited by 59 publications

(14 citation statements)

References 40 publications

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“…Micro-machining processes can also be advantageous in terms of productivity, efficiency, flexibility and cost-effectiveness when compared to these lithographic techniques (Anand andPatra, 2014, Asad et al, 2007). There are a number of issues that prevail in microscale machining which influence the underlying mechanics of the process and make machining a challenge (Liu et al, 2005).…”

Section: Micro-machiningmentioning

confidence: 99%

Fundamental Investigations Into Burr Formation and Damage Mechanisms in the Micro-Milling of a Biomedical Grade Polymer

Ervine

O’Donnell

Walsh

2015

Machining Science and Technology

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2 The demand for micro-machined polymer components has been rapidly growing for a number of years in various diverse applications. These polymer components often require high surface finishes and excellent dimensional accuracies, meeting these specifications requires a deeper understanding of material behavior and cutting performance during micro-machining. A lack of published literature relating to polymer machining increases the production challenge as cutting strategies employed are often based on trial and error with heuristic solutions developed. This work explains material behavior and machining outcomes by focusing on the study of the various damage mechanisms encountered during the micro-machining of a biomedical grade polymer. The importance of the material removal mechanism is highlighted with up-milling shown to produce a superior surface finish on average. The role of speed and feed in the generation of machined surfaces is examined with suboptimal settings shown to produce unwanted thermal influences and significant material deformations.

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Section: Micro-machiningmentioning

confidence: 99%

Fundamental Investigations Into Burr Formation and Damage Mechanisms in the Micro-Milling of a Biomedical Grade Polymer

Ervine

O’Donnell

Walsh

2015

Machining Science and Technology

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“…Some extensive research efforts have been reported to comprehend the milling mechanics, cutting reaction forces, tool-chip interface temperature, and machining-induced residual stress. In such studies, the main predictive modeling techniques to analyze the chip morphology and cutting reaction force include numerical, analytical, mechanistic, artificial intelligence, molecular dynamics, multi-scale modeling, and hybrid modeling approaches [10,11]. In the case of FE milling simulations, the predictive modeling techniques become quite challenging due to certain factors.…”

Section: Introductionmentioning

confidence: 99%

Numerical modeling and simulation of macro- to microscale chip considering size effect for optimum milling characteristics of AA2024T351

Saleem

Ijaz

Al‐Zahrani

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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This research work deals with the numerical modeling and analysis of macro-to microscaled milling of a strain rate-sensitive alloy AA2024T351. The milling computations of a semicircular slot are performed in Abaqus/Explicit by employing the Johnson-Cook thermo-elasto viscoplastic material damage model. The Coulomb friction model is applied at the contact interfaces of work piece and cutting tool. Due to the simultaneous effect of cutting feed and angular speed (ω r), the geometry of uncut chip is modeled with variable section thickness to adapt the trochoidal path. The configuration of the uncut chip undertakes the macro-to micromilling effect. This research effort uniquely explains a comprehensive modeling and milling computations at macro-to microscales to identify the imperative milling characteristics. The presented formulation in form of the modified Johnson-Cook constitutive equation explains the size effect during micromilling. A parametric sensitivity analysis is performed with four different cutting speeds (500, 600, 700, and 800 m/min) and two contact friction coefficients (0.2 and 0.3) while keeping the feed rate constant (0.2 mm/teeth). It was observed that cutting speed and contract friction coefficient play a pivotal role in cutting reaction force and chip-tool interface temperature. A temperature in the range of 141-167 °C is predicted with different cutting speeds. The percentage deviations of the simulated cutting forces from the published experimental results are found promising. The estimated deviation may be because of compromising some imperative factors in numerical model, such as cutter vibrations, tool wear effect, tool run-out, and limitations, to develop an exact trochoidal trajectory.

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“…There has been an increasing demand for high-precision miniaturized components in the fields of aerospace, biomedical, electronics, optics and precision instruments [1], the miniaturization of parts has become an inevitable choice. Micro-cutting at microscopic scale is not simply reduce the size of the macro-cutting, the physical phenomena and the basic rules of macroscopic cutting are no longer fully applicable because of the reduction of the size.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Material Constitutive Model in Mesoscopic Scale Cutting Process

Tian¹,

Han²,

Han³

2018

dtcse

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Abstract. Micro-machining can produce size effect under mesoscopic scale, by using the strain gradient plasticity theory of dislocation mechanism, considering the micro-structure characteristics of the material, the material constitutive model under mesoscopic scale is established, which can be used to explain the size effect of micro-machining. The material constitutive model under the mesoscopic scale derived from the theory is analyzed and studied based on oxygen -free copper, and the stress-strain curves and simulation results under different conditions are obtained in this article. The research shows that with the increase of cutting thickness, the stress-strain curve of the material will tend to the stress-strain curve of macro cutting.

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Modeling and Simulation of Mechanical Micro-Machining—A Review

Cited by 59 publications

References 40 publications

Fundamental Investigations Into Burr Formation and Damage Mechanisms in the Micro-Milling of a Biomedical Grade Polymer

Fundamental Investigations Into Burr Formation and Damage Mechanisms in the Micro-Milling of a Biomedical Grade Polymer

Numerical modeling and simulation of macro- to microscale chip considering size effect for optimum milling characteristics of AA2024T351

Analysis of Material Constitutive Model in Mesoscopic Scale Cutting Process

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