A comparative study of material phase effects on micro-machinability of multiphase materials

In the mechanical micro-machining of multiphase materials, the cutting process is undertaken at a length scale where material heterogeneity has to be considered. This has led to increasing interest in optimising the process parameters for micro-machining of such materials. In this study the micro-machinability of two steels, a predominantly ferrite material (AISI 1005) and a near-balanced ferrite/pearlite microstructure (AISI 1045) was studied. Workpiece sample deformation properties were characterised by nano-indentation testing. Additionally, metallographic grain size evaluation was undertaken for the workpiece microstructures. Surface roughness, workpiece microstructure and burr size for micro-machined parts as well as tool wear were examined over a range of feed rates. The results suggest that for micro-machined parts, differential elastic recovery between phases leads to higher surface roughness when the surface quality of micro-machined multiphase phase material is compared to that of single phase material. On the other hand, for single phase predominantly ferritic materials, reducing burr size and tool wear are major challenges. Thus, the paper elucidates on material property effects on surface and workpiece edge quality during micro-milling.

[1]  A. Minor,et al.  Indentation across size scales and disciplines: Recent developments in experimentation and modeling , 2007 .

[2]  K. Nakayama,et al.  TOPICS ON FUNDAMENTALS OF PRECISION MACHINING , 1997 .

[3]  István Mészáros,et al.  Micromilling of metallic materials , 2003 .

[4]  M. Elbestawi,et al.  Chip formation during microscale cutting of a medium carbon steel , 2006 .

[5]  Simon S. Park,et al.  Investigation of micro-cutting operations , 2006 .

[6]  H. Tritschler,et al.  Micro cutting of steel , 2004 .

[7]  Paul Mativenga,et al.  Evaluation and selection of hard coatings for micro milling of hardened tool steel , 2008 .

[8]  N. Moronuki,et al.  Effect of Material Properties on Ultra Precise Cutting Processes , 1988 .

[9]  A J Mian,et al.  Micromachining of coarse-grained multi-phase material , 2009 .

[10]  David Dornfeld,et al.  Analysis of Burr Formation Mechanism in Orthogonal Cutting , 1999 .

[11]  Junghwan Ahn,et al.  Effects of the friction coefficient on the minimum cutting thickness in micro cutting , 2005 .

[12]  J.-B. Park,et al.  Evaluation of machinability in the micro end milling of printed circuit boards , 2009 .

[13]  Lothar Bohn,et al.  Microstructure grooves with a width of less than 50 μm cut with ground hard metal micro end mills , 1999 .

[14]  David Dornfeld,et al.  Micro-Burr Formation and Minimization through Process Control , 2003 .

[15]  Chengfeng Li,et al.  Modelling and experimental analysis of the effects of tool wear, minimum chip thickness and micro tool geometry on the surface roughness in micro-end-milling , 2008 .

[16]  Paul Mativenga,et al.  Size effect and tool geometry in micromilling of tool steel , 2009 .

[17]  M. A. Elbestawi,et al.  Grain size and orientation effects when microcutting AISI 1045 steel , 2007 .

[18]  L. K. Gillespie,et al.  Deburring precision miniature parts , 1979 .

[19]  Andrzej Rosochowski,et al.  Micromilling: Material microstructure effects , 2006 .

[20]  Kazuo Nakayama,et al.  Burr Formation in Metal Cutting , 1987 .

[21]  Sangkee Min,et al.  Recent Advances in Mechanical Micromachining , 2006 .

[22]  Fengzhou Fang,et al.  On minimum exit-burr in micro cutting , 2004 .

[23]  Giuliano Bissacco,et al.  Size Effects on Surface Generation in Micro Milling of Hardened Tool Steel , 2006 .

[24]  Paul Mativenga,et al.  Tool wear modes in micro/mesoscale milling of hardened die steel , 2008 .

[25]  H. Zahouani,et al.  Understanding and quantification of elastic and plastic deformation during a scratch test , 1998 .

[26]  G. K. Lal,et al.  Transition from ploughing to cutting during machining with blunt tools , 1977 .

[27]  M. Elbestawi,et al.  Surface defects during microcutting , 2006 .

[28]  Richard E. DeVor,et al.  An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining , 2006 .

[29]  Richard E. DeVor,et al.  On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part I: Surface Generation , 2004 .

[30]  M. A. Elbestawi,et al.  The Effect of Microstructure on Chip Formation and Surface Defects in Microscale, Mesoscale, and Macroscale Cutting of Steel , 2006 .

[31]  Giuliano Bissacco,et al.  Micromilling of hardened tool steel for mould making applications , 2005 .

[32]  P. T. Blotter,et al.  The Formation and Properties of Machining Burrs , 1976 .

[33]  N. Moronuki,et al.  Experiments on the effect of material properties on microcutting processes , 1994 .

[34]  O. B. Ozdoganlar,et al.  An experimental investigation of micro-machinability of copper 101 using tungsten carbide micro-endmills , 2007 .

[35]  B. Ngoi,et al.  Effect of tool and workpiece anisotropy on microcutting processes , 2001 .

[36]  B. Ngoi,et al.  THE EFFECT OF MATERIAL MICROSTRUCTURE ON MICROCUTTING PROCESSES , 2001 .

[37]  H. Weule,et al.  Micro-Cutting of Steel to Meet New Requirements in Miniaturization , 2001 .