Springer Nature is making SARS-CoV-2 and COVID-19 research free. View research | View latest news | Sign up for updates

Researches on physical field evolution of micro-cutting of steel H13 by micron scale ceramic cutter based on finite element modeling

  • 196 Accesses

  • 7 Citations


The purpose of this study is to investigate the wear characteristics of ceramic cutter with size 1 μm for ultra micro-cutting of steel H13. The three-dimensional (3D) finite element model of micro-cutting has been developed, and micro-cutting conditions of simulation and material properties have been applied. The simulation results show that cutting forces along X and Z directions are more stable and smaller than the force along Y direction comparatively. And, the force fluctuation increases with rise of cutting speeds. The cutter wears increase with the rise of cutting speeds. There exist minor differences between maximum temperatures in cutter/workpiece during micro-cutting, and the deviation values are about 10 °C. Through these researches, some physical field evolution of micro-cutting parameters could be predicted, and it could be helpful to predict the variation of cutting force, cutter wears, and temperature evolutions. The obtained results could provide the fundamental and practical guidelines for choices of cutting speeds for the metal micro-cutting by ceramic cutter.

This is a preview of subscription content, log in to check access.


  1. 1.

    Liu CR, Guo YB (2000) Finite element analysis of the effect of sequential cuts and tool chip friction on residual stresses in a machined layer. Int J Mech Sci 42:1069–1086

  2. 2.

    Qin F, Gong X, Chou K (2011) Size effects in cutting with a diamond-coated tool, Proceedings of the ASME 2011 International Manufacturing Science and Engineering Conference, Corvallis, OR, 267–273

  3. 3.

    Hu HJ, Huang WJ (2013) Studies on wears of ultrafine-grained ceramic tool and common ceramic tool during hard turning using Archard wear model. Int J Adv Manuf Technol 69:31–39

  4. 4.

    Hu HJ, Huang WJ, Wu GS (2013) 3D finite element modeling and experimental researches on turning steel AISI1013 by nano-crystalline Al2O3 ceramics cutter. Int J Mach Mach Mater 14:295–310

  5. 5.

    Afazov SM, Ratchev SM, Segal J (2010) Modeling and simulation of micro-milling cutting forces. J Mater Process Technol 210:2154–2162

  6. 6.

    Chae J, Park SS, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46:313–332

  7. 7.

    Tansel IN, Arkan TT, Bao WY, Mahendrakar N, Shisler B, Smith D, McCool M (2000) Tool wear estimation in micro-machining. Part I: tool usage–cutting force relationship. Int J Mach Tools Manuf 40:599–608

  8. 8.

    Cui X, Zhao J, Zhou Y, Zheng G (2013) Damage mechanics analysis of failure mechanisms for ceramic cutting tools in intermittent turning. Eur J Mech A/Solids 37:139–149

  9. 9.

    Afazov SM, Zdebski D, Ratchev SM, Segal J, Liu S (2013) Effects of micro-milling conditions on the cutting forces and process stability. J Mater Process Technol 213:671–684

  10. 10.

    Hu HJ, Huang WJ (2013) Effects of turning speed on high-speed turning by ultrafine-grained ceramic tool based on 3D finite element method and experiments. Int J Adv Manuf Technol 67:907–915

  11. 11.

    Liu W, Liu S, Ma J, Kovacevic R (2014) Real-time monitoring of the laser hot-wire welding process. Opt Laser Technol 57:66–76

  12. 12.

    Liu W, Ma J, Yang G, Kovacevic R (2014) Hybrid laser-arc welding of advanced high-strength steel. J Mater Process Technol 214:2823–2833

  13. 13.

    Kong F, Liu W, Ma J, Levert E, Kovacevic R (2013) Feasibility study of laser welding assisted by filler wire for narrow-gap butt-jointed plates of high-strength steel. Weld World 57:693–699

  14. 14.

    Afazov SM, Ratchev SM, Segal J (2012) Prediction and experimental validation of micro-milling cutting forces of AISI H13 steel at hardness between 35 and 60 HRC. Int J Adv Manuf Technol 62:887–899

  15. 15.

    Aliakbari E, Baseri H (2012) Optimization of machining parameters in rotary EDM process by using the Taguchi method. Int J Adv Manuf Technol 62:1041–1053

  16. 16.

    Tang ZT, Liu ZQ, Pan YZ, Wan Y, Ai X (2009) The influence of tool flank wear on residual stresses induced by milling aluminum alloy. J Mater Process Technol 209:4502–4508

  17. 17.

    Sun H, Wan N, Chang Z, Mo R (2011) Approach to optimization of part machining service combination. Int J Adv Manuf Technol 56:767–776

  18. 18.

    Wang M, Wang J (2012) CHMM for tool condition monitoring and remaining useful life prediction. Int J Adv Manuf Technol 59:463–471

  19. 19.

    Shao F, Liu Z, Wan Y, Shi Z (2010) Finite element simulation of machining of Ti-6Al-4V alloy with thermodynamically constitutive equation. Int J Adv Manuf Technol 49:431–439

  20. 20.

    Wu ZG, Song M, He YH (2009) Effects of Er on the microstructure and mechanical properties of an as-extruded Al–Mg alloy. Mater Sci Eng A 504:183–187

  21. 21.

    Song M, Wu Z, He Y (2008) Effects of Yb on the mechanical properties and microstructures of an Al–Mg alloy. Mater Sci Eng A 497:519–523

Download references

Author information

Correspondence to Hongjun Hu.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Hu, H., Zhai, Z., Li, Y. et al. Researches on physical field evolution of micro-cutting of steel H13 by micron scale ceramic cutter based on finite element modeling. Int J Adv Manuf Technol 78, 1407–1414 (2015).

Download citation


  • Micron ceramic cutter
  • Micro-cutting
  • Wear characteristics
  • Cutting speed
  • Cutting force
  • Cutting temperature