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Single-flank machining strategy for ultraprecise single-point cutting of V-grooves

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Abstract

The increase in convenience and value of many industrial and household products due to their size and weight reduction over the years has triggered the rapid development of micromachining technologies. V-grooves have gained attention in micromachining due to their versatile use on a wide variety of products. To date, a double-flank axial cutting strategy involving a constant cutting depth set is commonly used in the fabrication of V-grooves. By contrast, the current study introduces a single-flank cutting strategy (SFCS) with two main implementations: constant chip thickness (CCT) and constant cutting area (CCA). The two implementations of the proposed SFCS were compared in terms of both experimental and numerical force results. The thorough comparison performed revealed advantages and disadvantages for both implementations in terms of cutting force magnitude, machining time, and surface quality obtained after a finishing pass. The results obtained revealed that a strong linear dependence exists between the area of material removed and the cutting force in the CCT implementation, whereas the CCA implementation is characterized by a quasi-constant cutting force magnitude owed to the constant area of material removed in each cutting pass. Moreover, while both implementations yielded surface quality within the optical surface quality range (Sa under 15 nm), the CCT variant is characterized by longer machining times and lower force levels, whereas the CCA implementation employs fully controllable cutting forces at preset levels. As such, the CCA implementation can be associated with stable cutting dynamics, predictable tool wear, and unanticipated tool breakage.

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Acknowledgements

The work presented in this study is the result of the collaboration between Western University (London, Ontario) and the National Research Council of Canada (London, Ontario).

Funding

Partial financial support was provided by the Natural Sciences and Engineering Research Council (NSERC) of Canada.

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Authors and Affiliations

  1. Mechanical and Materials Engineering, Western University, London, Canada

    Delfim Joao, Otoniel Rangel, Nicolas Milliken, O. Remus Tutunea-Fatan & Evgueni Bordatchev

  2. National Research Council of Canada, London, Canada

    Delfim Joao, Otoniel Rangel, Nicolas Milliken, O. Remus Tutunea-Fatan & Evgueni Bordatchev

Authors
  1. Delfim Joao
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  2. Otoniel Rangel
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  3. Nicolas Milliken
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  4. O. Remus Tutunea-Fatan
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  5. Evgueni Bordatchev
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All authors have contributed equally to this work.

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Correspondence to O. Remus Tutunea-Fatan.

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Joao, D., Rangel, O., Milliken, N. et al. Single-flank machining strategy for ultraprecise single-point cutting of V-grooves. Int J Adv Manuf Technol 120, 4505–4523 (2022). https://doi.org/10.1007/s00170-022-08732-0

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  • DOI: https://doi.org/10.1007/s00170-022-08732-0

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