Finite Element Simulation of Minimum Uncut Chip Thickness in Micro Mill-Grinding Ti6Al4V Based on Single-Edge Single-Grit Model

Abstract

The cutting edge radius Re leads to the minimum uncut chip thickness in micro machining. The single-edge single-grit model was developed for micro mill-grinding in this paper. Simulations for Ti6Al4V were performed in various cutting depths, and the minimum uncut chip thickness of micro mill-grinding was confirmed to be between 0.25Re and 0.3Re (approximate 0.275Re). Various grain heights of protrusion were investigated to discuss the influence of grain depths of cut on the minimum uncut chip thickness. The minimum uncut chip thickness will increase if the grinding debris forms, while it will get smaller if the grinding debris cant be generated.