Chip formation in microscale milling and correlation with acoustic emission signal

This work investigated the effects of different workpiece materials on chip formation and associated mechanisms in microcutting. The wavelet transformation technique was used to decompose acoustic emission (AE) signals generated from orthogonal micromilling of different workpiece materials. This allowed studying energy levels corresponding to deformation mechanisms. Resulting chip forms were characterised. The results indicated that the computed energies of decomposed frequency bands can be positivity correlated with chip morphology. The work provides significant and new knowledge on the utility and importance of AE signals in characterising chip formation in micromachining. Understanding chip formation mechanisms is important in managing the size effect in micromachining.

[1]  R. Komanduri,et al.  On Shear Instability in Machining a Nickel-Iron Base Superalloy , 1986 .

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

[3]  C. E. Thomas,et al.  Prospects for in-process diagnosis of metal cutting by monitoring vibration signals , 1987 .

[4]  D. Dornfeld,et al.  Acoustic emission during orthogonal metal cutting , 1980 .

[5]  Krzysztof Jemielniak,et al.  Chip form monitoring through advanced processing of cutting force sensor signals , 2006 .

[6]  Sabbir Rangwala,et al.  A study of acoustic emission generated during orthogonal metal cutting—1: Energy analysis , 1991 .

[7]  J. Raja,et al.  Multi-scale analysis of engineering surfaces , 1995 .

[8]  Xun Chen,et al.  Classification of the acoustic emission signals of rubbing, ploughing and cutting during single grit scratch tests , 2006 .

[9]  Paul Mativenga,et al.  Assessment of the machinability of Ti-6Al-4V alloy using the wear map approach , 2009 .

[10]  C. A. van Luttervelt,et al.  Recent Developments in Chip Control Research and Applications , 1993 .

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

[12]  G. Byrne,et al.  Observations on chip formation and acoustic emission in machining Ti–6Al–4V alloy , 2001 .

[13]  Yuichi Kanda,et al.  Identification of Chip Formation Mechanism through Acoustic Emission Measurements , 1984 .

[14]  Matthew A. Davies,et al.  On Chip Morphology, Tool Wear and Cutting Mechanics in Finish Hard Turning , 1996 .

[15]  J. T. Black.  Shear Front-Lamella Structure in Large Strain Plastic Deformation Processes , 1972 .

[16]  R. Komanduri,et al.  Some aspects of machining with negative rake tools simulating grinding , 1971 .

[17]  Yiğit Karpat,et al.  Investigation of the effect of cutting tool edge radius on material separation due to ductile fracture in machining , 2009 .

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

[19]  R. Komanduri,et al.  New observations on the mechanism of chip formation when machining titanium alloys , 1981 .

[20]  Kanji Ueda,et al.  Chip Formation Mechanism in Microcutting of an Amorphous Metal , 1992 .

[21]  Chi Fai Cheung,et al.  Elastic strain induced shear bands in the microcutting process , 2010 .

[22]  João Fernando Gomes de Oliveira,et al.  Precision manufacturing process monitoring with acoustic emission , 2006 .

[23]  D. Paul.  Detection of change in processes using wavelets , 1994, Proceedings of IEEE-SP International Symposium on Time- Frequency and Time-Scale Analysis.

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

[25]  Ibrahim N. Tansel,et al.  Micro-end-milling—I. Wear and breakage , 1998 .

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

[27]  Hiroaki Tanaka,et al.  Feasibility Study on Ultimate Accuracy in Microcutting Using Molecular Dynamics Simulation , 1993 .

[28]  Don A. Lucca,et al.  Effect of Tool Edge Geometry on Energy Dissipation in Ultraprecision Machining , 1993 .

[29]  Milton C. Shaw.  A new mechanism of plastic flow , 1980 .

[30]  C. Cheung,et al.  Materials induced vibration in ultra-precision machining , 1999 .

[31]  David Dornfeld,et al.  Modeling and Analysis of Acoustic Emission in Diamond Turning , 1996 .

[32]  R. Krishnamurthy,et al.  In-process tool wear and chip-form monitoring in face milling operation using acoustic emission. , 1994 .

[33]  R. Komanduri,et al.  On the Mechanics of Chip Segmentation In Machining , 1981 .

[34]  R. M'Saoubi,et al.  Role of phase and grain size on chip formation and material work hardening during machining of single and dual phase steels , 2004 .

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

[36]  Paul Mativenga,et al.  A comparative study of material phase effects on micro-machinability of multiphase materials , 2010 .

[37]  Kiyoshi Tamura,et al.  Size Effect in Metal-Cutting Force , 1968 .

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

[39]  Hiroaki Tanaka,et al.  Minimum thickness of cut in micromachining , 1992 .