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An analytical model for micro-cutting considering the cutting tool edge radius effect and material separation

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Abstract

Severe plastic deformation occurs in micro metal cutting process; meanwhile, new surfaces are generated due to the material separation caused by ductile fracture. The energy required for the formation of the new surfaces is of kJ/m2, which should not be neglected in the analysis of micro-cutting. In this work, an analytical model is developed focusing on the analyses of the micro metal cutting process with no stable built-up edge, in which the effects of both edge radius and material separation are taken into account. The cutting tool edge geometry is simplified with the effective rake angle. On the basis of slip-line field theory, the equation of the cutting power is derived. Applying the minimum energy principle, two nonlinear equations are obtained, through which the shear angle and the minimum chip thickness can be estimated simultaneously. The model is examined through the experiments; the investigations show that the calculation results of cutting force and shear angle agreed with the experimental measurements very well. The effects of fracture toughness, shear yield stress, and friction angle to the micro-cutting process are investigated. The numerical results show that the friction angle affects the cutting force and the shear angle greatly.

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Data availability

The data that support the findings of this study are available from the corresponding authors upon reasonable request.

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Funding

This work was supported by the National Key Research and Development Plan Project (No. 2018YFB1107403), the “111” Project of China (No. D17017), Jilin Province Scientific and Technological Development Program (No. 20190101005JH, No. 20180201057GX, No. 20190302076GX), and the Changchun Equipment and Technical Research Institute (WDZC2019JJ016).

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Authors and Affiliations

  1. School of Mechatronical Engineering, Changchun University of Science and Technology, Changchun, 130022, China

    Yiquan Li, Zhanjiang Yu, Jinkai Xu, Xiaozhou Li & Huadong Yu

Authors
  1. Yiquan Li
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  2. Zhanjiang Yu
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  3. Jinkai Xu
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  4. Xiaozhou Li
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  5. Huadong Yu
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Contributions

Yiquan Li and Huadong Yu constructed the theoretical model. Jinkai Xu and Xiaozhou Li designed the experiment set-up. Measurements were performed by Zhanjiang Yu, Yiquan Li, and Jinkai Xu. Zhanjiang Yu developed the MATLAB program. The numerical analyses were performed by Zhanjiang Yu and Yiquan Li. Huadong Yu and Yiquan Li analyzed the data and contributed to writing the manuscript. Huadong Yu supervised the project and the collaboration.

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Correspondence to Huadong Yu.

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Li, Y., Yu, Z., Xu, J. et al. An analytical model for micro-cutting considering the cutting tool edge radius effect and material separation. Int J Adv Manuf Technol 114, 97–105 (2021). https://doi.org/10.1007/s00170-020-06457-6

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  • DOI: https://doi.org/10.1007/s00170-020-06457-6

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