• Mougo, Adriane Lopes
• Campos, Fabio Oliveira
• Araujo, Anna Carla

Abstract

The minimum chip thickness is the lower limit value where cutting process occurs as it is studied in cutting metal. Below this value the process is usually modeled as forming. In micro end milling the chip thickness varies with the rotation angle from zero to the feed per tooth. This article presents a first effort to divide the cutting process in two phases: when the chip thickness is below the lower limit and when there is cutting mechanism. It is proposed to calculate differently those two forces: forming forces and cutting forces. It is presented an experimental study on micro milling aluminum alloy with different width of cut in order to identity the influence of the minimum chip thickness on the resultant forces. Using lower width of cut, the time during forming phase would be relatively higher. Experimental data is acquired using a micro dynamometer and the forces are analyzed. Tool wear and workpiece surface features were also investigated. The design of experiments considers one factor, the width of cut, with four levels. The machined workpiece showed good superficial quality for lower width of cut with less burr formation along the channel.

Topics

• impedance spectroscopy
• surface
• phase
• experiment
• grinding
• aluminium
• laser emission spectroscopy
• milling