The anisotropic behavior of the material microstructure when processing multiphase materials at microscale becomes an important factor that has to be considered throughout the machining process. This is especially the case when chip-loads and machined features are comparable in size to the cutting edge radius of the tool, and also similar in scale to the grain sizes of the phases present within the material microstructure. Therefore, there is a real need for reliable models, which can be used to simulate the surface generation process during microendmilling of multiphase materials.This paper presents a model to simulate the surface generation process during microendmilling of multiphase materials. The proposed model considers the effects of the following factors: the geometry of the cutting tool, the feed rate, and the workpiece material microstructure. Especially, variations of the minimum chip thickness at phase boundaries are considered by feeding maps of the material microstructure into the model. Thus, the model takes into account these variations that alter the machining mechanism from a proper cutting to ploughing and vice versa, and are the main cause of microburr formation. By applying the proposed model, it is possible to estimate more accurately the resulting roughness because the microburr formation dominates the surface generation process during microendmilling of multiphase materials. The proposed model was experimentally validated by machining two different samples of dual-phase steel under a range of chip-loads. The roughness of the resulting surfaces was measured and compared to the predictions of the proposed model under the same cutting conditions. The results show that the proposed model accurately predicts the roughness of the machined surfaces by taking into account the effects of material multiphase microstructure. Also, the developed model successfully elucidates the mechanism of microburr formation at the phase boundaries, and quantitatively describes its contributions to the resulting surface roughness after microendmilling.
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August 2012
Technical Briefs
Modeling the Material Microstructure Effects on the Surface Generation Process in Microendmilling of Dual-Phase Materials
A. M. Abdelrahman Elkaseer,
A. M. Abdelrahman Elkaseer
Institute of Mechanical and Manufacturing Engineering,
Cardiff School of Engineering,
Faculty of Engineering Production Engineering and Mechanical Design Department,
e-mail: ElkaseerAM@CF.AC.UK
Cardiff School of Engineering,
Cardiff University
,Cardiff, CF24 3AA, UK
;Faculty of Engineering Production Engineering and Mechanical Design Department,
Port Said University
,Port Said, 42526, Egypt
e-mail: ElkaseerAM@CF.AC.UK
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S. S. Dimov,
S. S. Dimov
School of Mechanical Engineering,
University of Birmingham
,Birmingham, B15 2TT
, UK
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M. Negm,
M. Negm
Institute of Mechanical and Manufacturing Engineering,
Cardiff School of Engineering,
Cardiff School of Engineering,
Cardiff University
,Cardiff, CF24 3AA
, UK
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R. Minev
R. Minev
Faculty of Engineering, Science and the Built Environment,
London South Bank University
,London, SE1 0AA
, UK
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A. M. Abdelrahman Elkaseer
Institute of Mechanical and Manufacturing Engineering,
Cardiff School of Engineering,
Faculty of Engineering Production Engineering and Mechanical Design Department,
e-mail: ElkaseerAM@CF.AC.UK
Cardiff School of Engineering,
Cardiff University
,Cardiff, CF24 3AA, UK
;Faculty of Engineering Production Engineering and Mechanical Design Department,
Port Said University
,Port Said, 42526, Egypt
e-mail: ElkaseerAM@CF.AC.UK
S. S. Dimov
School of Mechanical Engineering,
University of Birmingham
,Birmingham, B15 2TT
, UK
M. Negm
Institute of Mechanical and Manufacturing Engineering,
Cardiff School of Engineering,
Cardiff School of Engineering,
Cardiff University
,Cardiff, CF24 3AA
, UK
R. Minev
Faculty of Engineering, Science and the Built Environment,
London South Bank University
,London, SE1 0AA
, UK
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received October 1, 2010; final manuscript received May 10, 2012; published online June 26, 2012. Assoc. Editor: Kornel Ehmann.
J. Manuf. Sci. Eng. Aug 2012, 134(4): 044501 (10 pages)
Published Online: June 27, 2012
Article history
Received:
October 1, 2010
Revision Received:
May 10, 2012
Citation
Abdelrahman Elkaseer, A. M., Dimov, S. S., Popov, K. B., Negm, M., and Minev, R. (June 27, 2012). "Modeling the Material Microstructure Effects on the Surface Generation Process in Microendmilling of Dual-Phase Materials." ASME. J. Manuf. Sci. Eng. August 2012; 134(4): 044501. https://doi.org/10.1115/1.4006851
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