Abstract
Micro-milling is an emerging processing technology for machining micro- and high-precision three dimensional parts that require the use of various materials (with sizes ranging from tens of micrometers to a few millimeters) in the field of advanced manufacturing. Therefore, it can be applied to manufacture the micro parts, but new challenges are raised about parts with high surface quality. Herein, both surface formation and micro machined surface roughness models are studied, with the aim of solving complicated problems regarding the quality of surface finish when micro-milling metallic materials. From a theoretical point of view, the first model for surface formation processes considering the strain gradient plasticity theory was built in the area around the cutting edge, and the minimum uncut chip thickness equation was derived. The model accounts for the properties of the work material in tertiary and quaternary zones on the minimum chip thickness. A second model for micro machined surface roughness based on the relationship of kinematics between cutting process and cutter edge was also developed, which takes the influences of tool run out into account. Both proposed models were introduced to analyze the tendency of surface roughness for micro grooves. Both models were also used to justify experimental results. The results show that the developed surface roughness model could be useful in predicting both roughness parameters and trends as a function of cutting parameters.
Highlights
With the development of science and technology, micro structures and parts play more and more important roles in aerospace, biomedicine, power, energy, etc
The results showed that the built simulation model could predict surface topography
The surface formation model was developed based on the strain gradient plasticity of materials for the prediction of the minimum chip thickness
Summary
With the development of science and technology, micro structures and parts play more and more important roles in aerospace, biomedicine, power, energy, etc. Micro-scale milling has become an emerging mechanical machining process, which can be used to produce complex 3D micro parts with a variety of materials. It has a high material removal rate, low cost, and is easy to use [1]. The surface of machined material is not always ideal. Surface roughness refers to the micro geometric shape produced on the surface of material and has great influence on the performance of the parts. The surface area-to-volume ratio becomes higher as the size of micro devices reduces anywhere from several microns to tens of microns, resulting in surface effects playing a more important role. It is especially necessary to better understand surface characteristics and the related mechanisms
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