Diamond-coated cutting tools are known to machine complex materials with many benefits associated with the generation of lower temperatures between contact surfaces. However, the complexity associated with machining exotic materials at the micro-scale eludes many researchers who study phenomena pertinent to the development of new processes for novel micro-structured materials. The study investigated the use of a Lagrangian-Eulerian-formulated finite element program to analyze chip formation and thermal effects when micro-machining Ti6Al4V titanium alloy used for medical device applications. For the simulated machining conditions described in this paper, chip formation occurred when F C/F T >1 and burr formation occurred when F C/F T <1. In addition to the force conditions, when the ratio of feed per tooth to tool edge radius is approximately unity (f tooth/t r ∼1), the micro-machining process forms chips. When the ratio is decreased to equal 0.5 (f tooth/t r = 0.5), chip formation and burr formation exists simultaneously. However, when the ratio approaches an approximate value of 0.3 (f tooth/t r ∼0.3), burr formation is dominant. The study also provides an insight into the thermal effects of micro-machining that shows how vertical filament chemical vapor deposition (VFCVD)-coated tools maintain the integrity of the surfaces of the material as a function of simulated machining parameters. In conclusion, the computational analysis is compared with practical micro-machining results reported in the literature.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Apr 12, 2017
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