Tool edge radius effect on cutting temperature in micro-end-milling process

Abstract

The cutting temperature plays an important role in micro-scale cutting process due to the fact that the dimension of the micro-cutter is small and the value of micro-cutter wear is sensitive to temperature. In this paper, the temperature distribution of the micro-cutter in the micro-end-milling process has been investigated by numerical simulations and experimental approach. Micro-end-milling processes are modeled by the three-dimensional finite element method coupling thermal-mechanical effects. The microcutter cutting temperature distribution, the effect of various tool edge radii on cutting force, and the effective stress during micro-end-milling of aluminum alloy Al2024-T6 using a tungsten-carbide micro-cutter are investigated on. The simulation results show that with increase of tool edge radius the cutting force increases, while the effective stress and mean cutting temperature decreases slightly. In increasing the tool edge radius, the maximum effective stress and cutting temperature region of the micro-cutter occur from the rake face to the corner on the tool edge and the flank face. The tool edge radius has been found to be the major factor affecting micro-cutter temperature distribution. The experimental verification of the simulation model is carried out on a micro-end-milling process of aluminum alloy 2024-T6 with a high-precision infrared camera. The influence of tool edge radius on cutting temperature distribution was verified in experiments.

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

“…In addition, the tribological behaviour of TiAlN coatings reported that it had a coefficient of friction μ = 0.7 [48]. Previous studies on modelling the machining process of Al2024-T alloy used coefficient of friction between 0.3 and 0.7 [30,[49][50][51]. Therefore, the coefficient of friction of 0.7 was selected after a vigorous mesh study where it was varied from 0.4 to 0.8 used in previous studies.…”

Evaluation and Modeling of the Effect of Tool Edge Radius on Machined Surface Roughness in Turning UNS A92024-T351 Aluminum Alloy

“…In precision and ultraprecision machining, the feed rate is often in the same magnitude as the tool edge radius. The effect of the tool edge radius cannot be neglected because extensive experimental evidence has suggested that the tool edge radius significantly affects chip formation, 1-3 cutting forces, [4][5][6] cutting temperatures, 7 tool wear, 8 and surface integrity. 9 For example, Arif, Rahman, and San 5 found that tool edge radius affects crack propagation in the cutting zone in the ductile-mode machining of brittle materials, such as tungsten carbides.…”

A Finite Element Modeling Prediction in High Precision Milling Process of Aluminum 6082-T6

“…In addition to 2D analysis, the 3D FEM method provides additional analysis material to explore the effect of the cutting tool on chip flow and burr formation [13]. A 3D FEM in dry micro milling process studied chip formation such as plastic chip flow, plastic strain, principle stresses, and temperatures of titanium alloy Ti-6Al-4V [14].…”

“…A 3D FEM in dry micro milling process studied chip formation such as plastic chip flow, plastic strain, principle stresses, and temperatures of titanium alloy Ti-6Al-4V [14]. Another study [13] with 3D FEM investigated the effect of the cutting edge radius on temperature distribution, effective stress and simulated cutting forces in Al2024-T6 micro milling. Abouridouane et al [15] studied microstructure-based multiphase FEM of micro drilling ferritic-pearlitic carbon steels.…”