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Manufacturing and preparation of micro cutting tools: influence on chip formation and surface topography when micro cutting titanium

  • Frank Schneider
  • Christian Effgen
  • Benjamin KirschEmail author
  • Jan C. Aurich
Production Process
  • 25 Downloads

Abstract

Cutting edge preparation is widely used in conventional cutting processes. It stabilizes the cutting edge and is done to improve coating adhesion. However, the preparation of the cutting edge is accompanied by an increase in cutting edge roundness. This rounding results into larger effective negative rake angles, especially at small undeformed chip thicknesses, as they prevail in micro and ultraprecision processes. In this paper, the influence of the cutting edge micro geometry at very small undeformed chip thicknesses is investigated. A sharp, a rounded and a chamfered cutting edge are manufactured and examined at undeformed chip thicknesses of 0.4 µm, 5.2 µm and 10.0 µm. The resulting chip formation, forces and surface quality are examined when orthogonal cutting commercially pure titanium, a material used for example for bio-applications.

Keywords

Micro cutting Tool grinding Cutting edge preparation Chip formation Surface topography 

List of symbols

A

Chip cross section

ae,loc

Local width of cut

ae,nom

Nominal width of cut

b

Cutting width

d

Tool diameter

Fc

Cutting force

Fd

Thrust force

f

Feed

h

Undeformed chip thickness

h′

Chip thickness

lβ

Chamfer width

Ra

Center line average roughness

rβ

Cutting edge radius

∆r

Profile flattening

lsd

Cutting edge width

lsw

Cutting edge depth

Average cutting edge rounding

Sα

Cutting edge segment on rake face

Sγ

Cutting edge segment on flank face

vc

Cutting speed

α

Clearance angle

γ

Rake angle

γβ

Chamfer angle

γe

Effective rake angle

κ

k-factor

λ

Ratio between cutting edge radius and undeformed chip thickness

σ

Average standard deviation

φ

Cone angle

φa

Apex angle

Notes

Acknowledgements

Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)–Project number 172116086—SFB 926.

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Copyright information

© German Academic Society for Production Engineering (WGP) 2019

Authors and Affiliations

  • Frank Schneider
    • 1
  • Christian Effgen
    • 1
  • Benjamin Kirsch
    • 1
    Email author
  • Jan C. Aurich
    • 1
  1. 1.Institute for Manufacturing Technology and Production Systems, Department of Mechanical and Process EngineeringUniversity of KaiserslauternKaiserslauternGermany

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