Surface Generation Analysis in Micro End-Milling Considering the Influences of Grain

TL;DR

This paper investigates how different metal grain characteristics influence surface quality in micro end-milling, emphasizing the effects of anisotropic material properties and grain boundaries on chip formation and surface roughness.

Contribution

It provides a detailed analysis of grain influence on micro end-milling surface generation, incorporating experimental validation and theoretical insights into anisotropic material behavior.

Findings

Grain boundary effects cause discontinuous chips.

Friction coefficient and elastic modulus significantly affect surface quality.

Experimental results align well with theoretical predictions.

Abstract

Micro end-milling method is a universal micro manufacturing method, which can be used to fabricating complex 3D structures and parts with many materials. But compared with their micrometer order size, their surface roughness quality is not satisfied. In this paper, the different metal phase grains influences are researched, and the micro end-milling process is described while the material is anisotropic. In this paper, the physical characteristics of different grains, especially friction coefficient and elastic module, are very critical to determine the chip formation process and surface generation. The chip is often discontinues because of the grain boundary effect. Through the micro end-milling experiment, the bottom surface results correlate very well with the theory analysis.