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

AM Elkaseer, SS Dimov, DT Pham, KP Popov, L Olejnik, A Rosochowski

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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 µm 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 the effects of material homogeneity changes on the minimum chip thickness required for a robust micro-cutting process 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.
Original languageEnglish
Pages (from-to)1143-1155
Number of pages13
JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Volume232
Issue number7
Early online date22 Sep 2016
DOIs
Publication statusPublished - 22 Sep 2016

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Keywords

  • Micro-endmilling
  • material microstructure
  • grain size effects
  • surface finish
  • surface defects
  • equal channel angular pressing
  • atomic force microscope
  • minimum chip thickness

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