Abstract
Micromachining, which is used for various industrial purposes, requires the depth of cut and feed to be expressed in micrometers. Appropriate stock allowance and cutting conditions need to be selected to ensure that excess material is removed in the form of chips. To calculate the allowance, it is essential to take into account the tool nose radius, as this cutting parameter affects the minimum chip thickness. Theoretical and numerical studies on the topic predominate over experimental ones. This article describes a method and a test setup for determining the minimum chip thickness during turning. The workpiece was ground before turning to prevent radial runout and easily identify the transition zone. Contact and non-contact profilometers were used to measure surface profiles. The main aim of this study was to determine the tool–workpiece interaction stages and the cutting conditions under which material was removed as chips. Additionally, it was necessary to analyze how the feed, cutting speed, and edge radius influenced the minimum chip thickness. This parameter was found to be dependent on the depth of cut and feed. Elastic and plastic deformation and ploughing were observed when the feed rate was lower than the cutting edge radius.
Highlights
The manufacture of precision machine parts for the electrical, electronic, computer, biotechnological, and machine tool industries requires an understanding of the physical phenomena occurring at the microscale [1,2], especially when very low-depth cuts are involved [3,4]
For the DCMT 11T3-MF 1105 insert, hmin was read at a maximum feed (0.02 mm/rev) and was 0.69 rn; for the DCMT 11 T3 08 insert, the value of hmin read at a maximum feed (0.04 mm/rev) was 0.17 rn
The following conclusions were drawn from the experimental results: 1. The method employed to measure hmin requires that a workpiece with a simple shape and a high-resolution instrument be used to measure surface profiles so that the characteristic tool–workpiece interaction zones can be defined and accurately; 2
Summary
The manufacture of precision machine parts for the electrical, electronic, computer, biotechnological, and machine tool industries requires an understanding of the physical phenomena occurring at the microscale [1,2], especially when very low-depth cuts are involved [3,4]. One of the key factors affecting the surface quality in micromachining is the minimum chip thickness [5,6]. This parameter defines the minimum depth of cut at which, under specific cutting conditions, material is removed in the form of chip [7,8]. The depth of cut and other cutting parameters are used to optimize the process
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
