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Abstract
Friction modeling between the tool and the workpiece plays an important role in predicting the minimum cutting thickness during TC4 micro machining and finite element method (FEM) cutting simulation. In this study, a new three-region friction modeling is proposed to illustrate the material flow mechanism around the friction zone in micro cutting; estimate the stress distributions on the rake, edge, and clearance faces of the tool; and predict the stagnation point location and the minimum cutting thickness. The friction modeling is established by determining the distribution of normal and shear stress. Then, it is applied to calculate the stagnation point location on the edge face and predict the minimum cutting thickness. The stagnation point and the minimum cutting thickness are also observed and illustrated in the FEM simulation. Micro cutting experiments are conducted to validate the accuracy of the friction and the minimum cutting thickness modeling. Comparison results show that the proposed friction model illustrates the relationship between the normal and sheer stress on the tool surface, thereby validating the modeling method of the minimum cutting thickness in micro cutting.
Highlights
1.1 Research on the minimum cutting thicknessWith the fast increasing demand of miniature components and products in fields such as aerospace, medical equipment, and electronic communication devices, the manufacturing methods of micro-scale parts have become a research hotspot
We proposed a theoretical method to predict the minimum cutting thickness during micro cutting
The friction modeling was established by determining the distributions of normal and shear stress to identify the stagnation point location on the edge face and predict the minimum cutting thickness
Summary
With the fast increasing demand of miniature components and products in fields such as aerospace, medical equipment, and electronic communication devices, the manufacturing methods of micro-scale parts have become a research hotspot. The minimum cutting thickness is an important parameter in micro cutting because it influences machining accuracy and tool wear. Building a prediction model for the minimum cutting thickness is essential to understand the mechanics of micro cutting and improve the quality of processing. Friction plays a dominant role in predicting the minimum cutting thickness [1]. Developing a prediction method for the minimum cutting thickness is valuable. Agmell et al [4] proposed a model that builds a connection between the minimum cutting thickness and the stagnation point. Ee et al [6] proposed that cutting parameters influence the stagnation point. This paper further discusses the friction around the cutting zone to determine the stagnation point location from the perspective of the minimum cutting thickness
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