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Experimental Study on the Minimum Undeformed Chip Thickness Based on Effective Rake Angle in Micro Milling.

Xian Wu1, Li Liu2, Mingyang Du1

  • 1College of Mechanical Engineering and Automation, Huaqiao University, Xiamen 361021 China.

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Summary

Minimum undeformed chip thickness in micro milling causes unstable cutting and poor surface finish. This study quantifies this thickness and its impact on micro part manufacturing.

Keywords:
effective rake anglemicro millingminimum undeformed chip thicknesssize effect

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Mechanical Engineering

Background:

  • Micro milling is a key process for micro-scale part fabrication.
  • Key micro milling characteristics include minimum undeformed chip thickness, effective rake angle, and size effect, which are interrelated.
  • Understanding these parameters is crucial for optimizing micro milling processes.

Purpose of the Study:

  • To propose an averaging method for quantitatively estimating the effective rake angle during micro milling.
  • To explain and determine the minimum undeformed chip thickness (0.17 * tool cutting edge radius) based on the effective rake angle.
  • To experimentally investigate the effects of minimum undeformed chip thickness on micro milling.

Main Methods:

  • Development and application of an averaging method to calculate the effective rake angle.
  • Analytical determination of the minimum undeformed chip thickness.
  • Conducting micro milling experiments to observe the impact of varying minimum undeformed chip thickness.

Main Results:

  • Minimum undeformed chip thickness leads to process instability and uneven cutting force signals.
  • Frequency domain analysis reveals dense characteristic frequency distributions.
  • A dominant ploughing effect results in increased specific cutting energy and degraded surface roughness.

Conclusions:

  • The effective rake angle is a critical parameter influencing micro milling characteristics.
  • Minimum undeformed chip thickness significantly impacts process stability, cutting forces, and surface quality.
  • Controlling minimum undeformed chip thickness is essential for achieving high-quality micro parts through milling.