Title: Meso/micro scale milling for micro-manufacturing

Authors: A. Dhanorker, T. Ozel

Addresses: Department of Industrial and Systems Engineering, Rutgers University, Piscataway, NJ 08854-8018, USA. ' Department of Industrial and Systems Engineering, Rutgers University, Piscataway, NJ 08854-8018, USA

Abstract: Meso/micro scale milling is a direct operation to manufacture miniature parts. In this paper, experimental and modelling studies on meso/micro milling of AL 2024-T6 aluminum and AISI 4340 steel are presented. Experiments include dynamic force measurements. The finite element modelling of meso/micro-milling is also conducted to predict chip formation and temperature fields. Size effects and minimum chip thickness related to edge radius and chip load on the workpiece deformations are also investigated. Process simulations are validated for force predictions.

Keywords: micromilling; micromachining; finite element modelling; FEM; size effect; minimum chip thickness; aluminium; steel; chip formation; workpiece deformation; process simulationp force prediction; micromanufacturing; temperature.

DOI: 10.1504/IJMMS.2008.018273

International Journal of Mechatronics and Manufacturing Systems, 2008 Vol.1 No.1, pp.23 - 42

Published online: 14 May 2008 *

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