This paper discusses the development of an enhanced, static model of chip formation in micromilling processes that is able to describe the intermittency of the chip formation observed at low feeds per tooth due to the dominance of the minimum chip thickness effect. Experimental analyses demonstrate the validity of the proposed model by verifying the level of periodicity in the cutting forces present at various feeds per tooth. A key finding of this study is the identification of a local maximum in the radial thrust forces in the micromilling process during the noncutting regime, at feeds per tooth that are of the order of the minimum chip thickness. To overcome the challenges in the direct measurement of the minimum chip thickness, this paper presents a method for estimating the minimum chip thickness of various combinations of tools and workpiece materials based on easily attainable cutting-force data. A discussion on the selection of process parameters to avoid intermittent chip formation is also presented.
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e-mail: rmayor@umich.edu
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November 2004
Technical Papers
A Static Model of Chip Formation in Microscale Milling
Chang-Ju Kim,
Chang-Ju Kim
S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109
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J. Rhett Mayor,
e-mail: rmayor@umich.edu
J. Rhett Mayor
S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109
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Jun Ni, Professor
Jun Ni, Professor
S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109
Search for other works by this author on:
Chang-Ju Kim
S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109
J. Rhett Mayor
S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109
e-mail: rmayor@umich.edu
Jun Ni, Professor
S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February 17, 2004. Revised July 22, 2004. Associate Editor: D.-W. Cho.
J. Manuf. Sci. Eng. Nov 2004, 126(4): 710-718 (9 pages)
Published Online: February 4, 2005
Article history
Received:
February 17, 2004
Revised:
July 22, 2004
Online:
February 4, 2005
Citation
Kim , C., Mayor, J. R., and Ni, J. (February 4, 2005). "A Static Model of Chip Formation in Microscale Milling ." ASME. J. Manuf. Sci. Eng. November 2004; 126(4): 710–718. https://doi.org/10.1115/1.1813475
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