Material microstructure effects in micro-endmilling of Cu99.9E

Ahmed M. Elkaseer , S.S. Dimov , D.T. Pham , Lech Olejnik , K.P. Popov , Andrzej Rosochowski

Abstract

This article presents an investigation of the machining response of metallurgically and mechanically modified materials at the micro-scale. Tests were conducted that involved micro-milling slots in coarse-grained Cu99.9E with an average grain size of 30 mm and ultrafine-grained Cu99.9E with an average grain size of 200 nm, produced by equal channel angular pressing. A new method based on atomic force microscope measurements is proposed for assessing materials’ microstructure effects in micro-machining, that is, the effects of material homogeneity changes on the minimum chip thickness required for a robust micro-cutting processes with a minimum surface roughness. The investigation has shown that by refining the material microstructure the minimum chip thickness can be reduced and a high surface finish can be obtained. Also, it was concluded that material homogeneity improvements lead to a reduction in surface roughness and surface defects in micro-cutting
Author Ahmed M. Elkaseer - Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Said, Egypt
Ahmed M. Elkaseer,,
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, S.S. Dimov - Department of Mechanical Engineering, University of Birmingham, Birmingham, UK
S.S. Dimov,,
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, D.T. Pham - Department of Mechanical Engineering, University of Birmingham, Birmingham, UK
D.T. Pham,,
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, Lech Olejnik ITW
Lech Olejnik,,
- The Institute of Manufacturing Processes
, K.P. Popov - Faculty of Computing, Engineering and Science, University of South Wales, Pontypridd, UK
K.P. Popov,,
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, Andrzej Rosochowski - University of Strathclyde, Dept. Design Manufacture & Engineering Management, UK
Andrzej Rosochowski,,
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Journal seriesProceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture, ISSN 0954-4054
Issue year2016
Vol230
Pages1-13
Publication size in sheets0.6
Keywords in EnglishMicro-endmilling, material microstructure, grain size effects, surface finish, surface defects, equal channel angular pressing, atomic force microscope, minimum chip thickness
DOIDOI:10.1177/0954405416666898
URL http://journals.sagepub.com/doi/abs/10.1177/0954405416666898
Languageen angielski
Score (nominal)25
Publication indicators WoS Impact Factor: 2016 = 1.366 (2) - 2016=1.386 (5)
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