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Determination of minimum uncut chip thickness and size effects in micro-milling of P-20 die steel using surface quality and process signal parameters

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Abstract

Prior to a critical value of uncut chip thickness (UCT) or the so-called minimum uncut chip thickness (MUCT), the micro milling process is affected by ploughing which causes deterioration of surface quality and reduction of tool life. Stringent surface quality is the major concern during micro milling of P-20 die steel as it has wide application in preparation of micro injection mould. Again, this MUCT value depends upon the workpiece, cutting tool material and its geometry. In this article, we tried to determine MUCT and size effects by considering the variations of surface quality parameters and process signals with the ratio of h/re (UCT (h) to edge radius(re)). MUCT value was determined to be 0.75–1 μm or critical h/re value was found to be in the range of 0.25–0.33. Comprehensive analysis of tool wear and chip morphology with size effect have been instituted those were lacking in the earlier literatures. Curled and helical chips were obtained at feed rate higher than MUCT value, whereas the chips with arbitrary shapes were noticed at feed rates below MUCT. Lamellar structures were observed at the free surface of the chip having both inclined and vertical orientation. Edge rounding, coating delamination and built-up edge formation were observed due to size effect at feed value below MUCT.

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Funding

This article is a part of the bilateral research project “Multi-sensors based intelligent tool condition monitoring in mechanical micro-machining” supported jointly by project no. INT/HUN/P-01/2012 and project number TÉT_10-1-2011-0233 funded by DST, Govt. of India and NIH, Govt. of Hungary, respectively.

This article is also partially supported by DST, Govt. of India through research project No. INT/RUS/RFBR/P-226 and by RFBR through research project No. 15-58-45017 ИНД_a.

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Authors and Affiliations

  1. Department of Mechanical Engineering, IIT Patna, Patna, 801103, India

    Priyabrata Sahoo & Karali Patra

  2. Department of Manufacturing Science and Engineering, Budapest University of Technology and Economics, Budapest, H-1111, Hungary

    Tibor Szalay

  3. South Ural State University, 76, Lenin Avenue, Chelyabinsk, Russian Federation, 454080

    Karali Patra & Aleksandr A. Dyakonov

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  1. Priyabrata Sahoo
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  2. Karali Patra
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Correspondence to Karali Patra.

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Sahoo, P., Patra, K., Szalay, T. et al. Determination of minimum uncut chip thickness and size effects in micro-milling of P-20 die steel using surface quality and process signal parameters. Int J Adv Manuf Technol 106, 4675–4691 (2020). https://doi.org/10.1007/s00170-020-04926-6

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