On the Modeling and Analysis of Machining Performance in Microendmilling
The surface generation process in the micro-endmilling of both single phase and multi-phase workpiece materials was also examined. 508 micron diameter endmills with edge radii of 2 and 5 microns were used to machine slots in ferrite, pearlite and two ductile iron materials at feedrates ranging from 0.25 to 3.0 microns/flute. A surface generation model to predict the surface roughness for the slot floor centerline is then developed based on the minimum chip thickness concept. Two phenomena were found to combine to generate an optimal feedrate for the surface generation of single phase materials, the geometric effect of the tool and process geometry and the minimum chip thickness effect. The surface roughness measurements for the ductile iron workpieces indicate that the micro-milling surface generation process for multi-phase workpiece materials is also affected by the interrupted chip formation process as the cutting edge moves between phases resulting in burrs at the phase boundaries and the associated increases in surface roughness.
University of Illinois - Urbana-Champaign
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University of Illinois at Urbana-Champaign