Abstract
This paper discusses an experimental approach to assess the machining characteristics in microscale end milling operation through a systematic experimentation procedure. Microchannels were machined on brass plates using a carbide end mill of 1 mm diameter to analyze the effect of chip load (feed per tooth) and cutting speed on the surface roughness, specific cutting pressure, and cutting forces during microend milling operation. The tangential and radial components of forces were analyzed with the help of a three-dimensional model using the force signals acquired through KISTLER dynamometer. Feed per tooth and the interaction of cutting speed and chip load were identified as the critical parameters affecting the surface roughness of microchannel. Applying the concept of elastic recovery on the side wall surface of microchannels, the minimum chip thickness during the above micromilling operation was evaluated as 0.97 μm, and the result was validated by the drastic increase in specific cutting pressure and erratic behavior of cutting forces below a chip load of 1 μm.
Similar content being viewed by others
References
Chae J, Park SS, Freiheit T (2006) Investigation of micro cutting operations. Int J Mach Tools Manuf 46:313–332
Mikrotool Pte Ltd Website: http://www.mikrotools.com/products and services, accessed on 18 May 2007.
Microlathes Website: http://lathes.jrbentley.com/modeltaig, accessed on 18 November 2007
Microendmills Website: http://www.metamasa.com/catalog/diximicro, accessed on 10 January 2008.
Amit Srivastava, Suhas S. Joshi, R. Balasubramaniam, V.K. Suri (2007) Response surface method-based analysis of width and depth of micro channels in Excimer laser ablation, Proceedings of International Conference on Precision, Meso, Micro and Nano Engineering (COPEN): 105–110
M. Rahman, H.S. Lim, K.S. Neo, A. Senthil Kumar, Y S Wong, X P Li (2006), Tool based micro-machining and nano surface generation, Proceedings of International Conference on Precision, Meso, Micro and Nano Engineering (COPEN): 31–45
Kim C-J, Mayor JR, Ni J (2004) A static model of chip formation in micro scale milling. J Manuf Sci Eng 126:710–718
Liu X, DeVor RE, Kapoor SG (2004) The mechanics of machining at micro scale: assessment of the current state of the science. J Manuf Sci Eng 126:666–678
Rahman M, Senthil Kumar A, Prakash JRS (2001) Micro milling of pure copper. J Mater Process Technol 116:39–43
Zaman MT, Senthil Kumar A, Rahman M, Sreeram S (2006) A three-dimensional analytical cutting force model for micro end milling operation. Int J Mach Tools Manuf 46:353–366
Liu X, Devor RE, Kapoor SG (2006) An analytical model for the prediction of minimum chip thickness in micromachining. J Manuf Sci Eng 128:474–481
Sooraj VS (2008) Theoretical and experimental investigations on mechanical micro machining (M3), M.Tech Thesis, Department of Mechanical Engineering, NITC, Calicut, Kerala, India
Ng CK, Melkote SN, Rahman M, Senthil Kumar A (2006) Experimental study of micro-and nano-scale cutting of aluminium 7075-T6. Int J Mach Tools Manuf 46:929–936
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Sooraj, V.S., Mathew, J. An experimental investigation on the machining characteristics of microscale end milling. Int J Adv Manuf Technol 56, 951–958 (2011). https://doi.org/10.1007/s00170-011-3237-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-011-3237-2