Abstract
The formation of chip and the machined surface is investigated, taking the cutter’s rounding radius into account. On that basis, it is possible to identify the point at which the material in the stagnant zone begins to separate. The proposed model describing the separation of cut material permits determination of the minimum possible chip thickness in cutting.
Similar content being viewed by others
REFERENCES
Wan, M., Wen, D., Ma, Y.C., and Zhang, W.H., On material separation and cutting force prediction in micro milling through involving the effect of dead metal zone, Int. J. Mach. Tools Manuf., 2019, vol. 146, pp. 1–14.
Altintas, Y., Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, Cambridge: Cambridge Univ. Press, 2012, 2nd ed.
Yuan, H., Wan, M., and Yang, Y., Design of a tunable mass damper for mitigating vibrations in milling of cylindrical parts, Chin. J. Aeronaut., 2019, vol. 32, pp. 748–758.
Bissacco, G., Hansen, H.N., and Slunsky, J., Modeling the cutting edge radius size effect for force prediction in micro milling, CIRP Ann., 2008, vol. 57, no. 1, pp. 113–116.
Jin, X. and Altintas, Y., Prediction of micro-milling forces with finite element method, J. Mater. Process. Technol., 2012, vol. 212, no. 3, pp. 542–552.
Jin, X. and Altintas, Y., Slip-line field model of micro-cutting process with round tool edge effect, J. Mater. Process. Technol., 2011, vol. 211, no. 3, pp. 339–355.
Yun, H.T., Heo, S., Min, K.L., Min, B.K., and Sang, J.L., Ploughing detection in micromilling processes using the cutting force signal, Int. J. Mach. Tools Manuf., 2011, vol. 51, no. 5, pp. 377–382.
Guo, Y.B. and Chou, Y.K., The determination of ploughing force and its influence on material properties in metal cutting, J. Mater. Process. Technol., 2004, vol. 48, no. 3, pp. 368–375.
Wang, J.J.J. and Zheng, C.M., Identification of shearing and ploughing cutting constants from average forces in ball-end milling, Int. J. Mach. Tools Manuf., 2002, vol. 42, no. 6, pp. 695–705.
Waldorf, D.J., DeVor, R.E., and Kapoor, S.G., A slip-line field for ploughing during orthogonal cutting, J. Manuf. Sci. Eng., 1998, vol. 120, no. 4, pp. 693–699.
Yuan, Z., Zhou, M., and Dong, S., Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining, J. Mater. Process. Technol., 1996, vol. 62, no. 4, pp. 327–330.
Lai, X., Li, H., Li, C., Lin, Z., and Ni, J., Modeling and analysis of micro scale milling considering size effect, micro cutter edge radius and minimum chip thickness, Int. J. Mach. Tools Manuf., 2008, vol. 48, no. 1, pp. 1–14.
Woon, K., Rahman, M., Neo, K., and Liu, K., The effect of tool edge radius on the contact phenomenon of tool-based micromachining, Int. J. Mach. Tools Manuf., 2008, vol. 48, nos. 12–13, pp. 1395–1407.
Son, S.M., Han, S.L., and Ahn, J.H., Effects of the friction coefficient on the minimum cutting thickness in micro cutting, Int. J. Mach. Tools Manuf., 2005, vol. 45, no. 4, pp. 529–535.
Malekian, M., Mostofa, M.G., Park, S.S., and Jun, M.B.G., Modeling of minimum uncut chip thickness in micro machining of aluminum, J. Mater. Process. Technol., 2012, vol. 212, no. 3, pp. 553–559.
Abdelmoneim, M.E. and Scrutton, R., Tool edge roundness and stable build-up formation in finish machining, J. Eng. Ind., 1974, vol. 96, no. 4, pp. 1258–1267.
Ozturk, S. and Altan, E., A slip-line approach to the machining with rounded-edge tool, Int. J. Adv. Manuf. Technol., 2012, vol. 63, nos. 5–8, pp. 513–522.
Basuray, P., Misra, B., and Lal, G., Transition from ploughing to cutting during machining with blunt tools, Wear, 1977, vol. 43, no. 3, pp. 341–349.
Wan, L. and Wang, D., Numerical analysis of the formation of the dead metal zone with different tools in orthogonal cutting, Simul. Model. Pract. Theory, 2015, vol. 56, pp. 1–15.
Long, Y. and Huang, Y., Force modeling under dead metal zone effect in orthogonal cutting with chamfered tools, Trans. North Am. Manuf. Res. Inst. SME, 2005, vol. 33, pp. 573–580.
Wallen, P., Jacobson, S., and Hogmark, S., Intermittent metal cutting at small cutting depths-1. Dead zone phenomena and surface finish, Int. J. Mach. Tools Manuf., 1988, vol. 28, no. 4, pp. 515–528.
Rechenko, D.S., The study of the process of difficult-to-machine materials cutting at the micro-level, Obrab. Met., 2019, vol. 21, no. 2, pp. 18–25.
Pereverzev, P.P. and Pimenov, D.Yu., Grinding force model allowing for dulling of abrasive wheel cutting grains in plunge cylindrical grinding, J. Frict. Wear, 2016, vol. 37, pp. 60–65.
Funding
Financial support was provided by the Russian President’s Council on Grants for Young Scientists and Leading Scientific Institutions (grant MD-345.2020.8).
Author information
Authors and Affiliations
Corresponding author
Additional information
Translated by B. Gilbert
About this article
Cite this article
Rechenko, D.S., Balova, D.G. Mechanics of Microcutting and Stagnant-Zone Formation. Russ. Engin. Res. 41, 236–239 (2021). https://doi.org/10.3103/S1068798X2103014X
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.3103/S1068798X2103014X