Title: Finite element analysis of mechanical micromilling processes

Authors: M.J. Jackson, G.M. Robinson, W. Ahmed

Addresses: Centre for Advanced Manufacturing, MET, College of Technology, Purdue University, 401 North Grant Street, West Lafayette, IN 47907-2021, USA. ' Centre for Advanced Manufacturing, MET, College of Technology, Purdue University, 401 North Grant Street, West Lafayette, IN 47907-2021, USA. ' School of Physical Sciences, Computing and Technology, University of Central Lancashire, Preston, Lancashire, PR1 4BU, UK

Abstract: The analysis of the micro milling process is described in this paper. The present work not only compares various computational approaches to the solution of shear plane and tool face temperatures, but also explains why there is a discrepancy when calculating temperatures generated during the micromachining process. The paper shows that the temperature of the shear plane never exceeds 35°C when micro milling at spindle speeds in excess of 250,000 revolutions per minute. The paper also explains how machining AISI 1015 steel presents significant challenges to tool wear especially at high cutting speeds.

Keywords: micromachining; computational analysis; finite element analysis; FEA; micromilling; tool wear; high speed machining; shear plane temperature; tool face temperature; steel machining.

DOI: 10.1504/IJNM.2009.027054

International Journal of Nanomanufacturing, 2009 Vol.3 No.1/2, pp.112 - 132

Published online: 13 Jul 2009 *

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