Micro-Cutting

Kai Cheng, Brunel University, UKProfessor Kai Cheng holds the chair professorship in Manufacturing Systems at Brunel University. His current research interests focus on micro manufacturing, design of precision machine tools, and global/sustainable manufacturing and systems. Professor Cheng has published over 160 papers in learned international journals and refereed conferences, authored/edited 5 books and contributed 6 book chapters.Professor Cheng is a fellow of the IET and IMechE. He is the head of the Advanced Manufacturing and Enterprise Engineering (AMEE) Department at Brunel, which consists of 10 academics and over 30 research assistants and PhD students. Professor Cheng is the European editor of the International Journal of Advanced Manufacturing Technology and a member of the editorial board of International Journal of Machine Tools and Manufacture.

• List of Contributors xiSeries Preface xiiiPreface xvPart One Fundamentals 11 Overview of Micro Cutting 3Dehong Huo and Kai Cheng1.1 Background and Scope 31.1.1 Micro Manufacturing 31.1.2 History and Development Process of Micro Cutting 51.1.3 Definition and Scope of Micro Cutting 71.1.4 Micro Cutting and Nanometric Cutting 81.2 Materials in Micro Cutting 101.3 Micro Cutting Processes 111.3.1 Micro Turning 121.3.2 Micro Milling 121.3.3 Micro Drilling 131.3.4 Micro Grinding 141.4 Micro Cutting Framework 14References 162 Micro Cutting Mechanics 19Dehong Huo and Kai Cheng2.1 Introduction 192.2 Characterization of Micro Cutting 202.2.1 Micro Cutting and Ultra-Precision Machining 212.2.2 Enabling Technologies for Micro Cutting 222.3 Micro Cutting Mechanics 252.3.1 Size Effects 262.3.2 Chip Formation and Minimum Chip Thickness 272.3.3 Specific Cutting Energy and Micro Cutting Force Modelling 292.3.4 Surface Generation and Burr Formation 332.4 Micro Machinability Issues and the Scientific Approaches 392.4.1 Vibration Assisted Micro Cutting 402.4.2 Laser Assisted Micro Cutting 402.5 Summary 41References 423 Micro Tooling Design and Manufacturing 45Paul T. Mativenga, Ampara Aramcharoen and Dehong Huo3.1 Tool Size and Machining Scale 453.2 Manufacturing Methods for Solid Shank Micro Tools 463.3 Coatings and Coated Solid Shank Micro Tools 483.3.1 Closed Field Unbalanced Magnetron Sputter Ion Plating (CFUBMSIP) 503.3.2 Coating Layout 503.4 Importance of Coated Micro Tools 523.5 Diamond Micro Cutting Tools 533.6 Micro Cutting Tool Wear 553.7 Smart Cutting Tools 58References 594 Ultraprecision and Micro Machine Tools for Micro Cutting 63Christian Brecher and Christian Wenzel4.1 Introduction 634.2 Components of High Precision Machine Tools 644.2.1 Machine Base Materials 654.2.2 Drive Systems 66 4.2.3 Guidance Systems 694.2.4 Control Systems and Amplifiers 704.3 Diamond Turning Machines and Components 704.3.1 Typical Machine Setup 714.3.2 Market Comparison 734.3.3 Fast Tool Servo Technology 784.4 Precision Milling Machines 79References 855 Engineering Materials for Micro Cutting 87Sathyan Subbiah and Shreyes N. Melkote5.1 Introduction 875.2 ‘Size’ Effects 885.3 Strain and Stress in Cutting 905.4 Elastic and Plastic Behaviours at the Micro-scale 94 5.5 Fracture 995.6 Metals, Brittle Materials and Others 1055.6.1 Pure Materials 105 5.6.2 Ductile Metals 106 5.6.3 Brittle Materials – Glass, Silicon, Germanium, Tungsten Carbide 107 5.6.4 Other Materials – Amorphous Alloys, Graphene and Embedded Polymers 108 5.7 Summary 111 References 1126 Modelling and Simulation of Micro Cutting 115Ying-Chun Liang, Qing-Shun Bai and Jia-Xuan Chen6.1 FE modelling and Analysis 1166.1.1 Finite Element Model 1166.1.2 Simulation on Micro-burr Formation 1176.1.3 Influence of the Tool Edge Radius on Cutting Forces 1186.1.4 Stress Distribution on the Micro-cutter 1206.1.5 Micro-tool-tip Breakage 1206.1.6 Thermal Analysis on Micro Cutting 1236.2 Molecular Dynamics (MD) Modelling and Analysis 1246.2.1 MD Modelling Process and Simulation 1246.2.2 Modelling Analysis of Micro Cutting 1276.2.3 Scratching Simulation by Using MD 1286.2.4 Friction and Wear Simulation by Using MD 1326.2.5 Effect of the Crystal Plane of Single Crystal and Multicrystalline 1356.2.6 Improvement of the MD Simulation Capability 1376.3 Multiscale Modelling and Analysis 1386.3.1 Advance in Multiscale Simulation Methods 1406.3.2 Applications of Multiscale Simulation in Micro Cutting Processes 1436.3.3 Research Challenges and Future Trends 1476.4 Summary 148References 148Part Two Applications 1537 Diamond Turning and Micro Turning 155Dehong Huo and Kai Cheng7.1 Introduction 1557.2 Ultra-precision Diamond Turning 1557.2.1 A Historical Perspective of Diamond Turning 1567.2.2 Material Perspectives 1587.2.3 Micro Structuring by Diamond Turning 1597.3 Micro Turning 1667.3.1 Micro Turning Tool Fabrication 1667.3.2 Micro Machines for Micro Turning 1717.3.3 Size Effect Arising from Micro Turning 1787.4 Challenges Arising from Micro Turning 182References 1828 Micro Milling: The State-of-the-art Approach Towards Applications 185Tao Wu and Kai Cheng8.1 Introduction 1858.2 Fundamental Elements in Micro Milling 1868.2.1 Micro Milling Machines 1878.2.2 Cutting Tools 1898.2.3 Process Conditions 1958.2.4 Work Materials 1978.3 Micro Milling Mechanics 1988.3.1 Size Effect in Micro-Scale Cutting 1988.3.2 Minimum Chip Thickness 2008.3.3 Work Micro Structure Effect 2038.4 Modelling of the Micro Milling Process 2058.4.1 Finite Element Modelling 2068.4.2 Mechanistic Modelling 2088.5 Metrology and Instrumentation 2128.5.1 3D Surface Profilers 2128.5.2 Microscopes 2128.5.3 Process Monitoring Sensors and Systems 2148.6 Scientific and Technological Challenges 2178.6.1 Tool Run-out 2178.6.2 Tool Wear and Life 2188.6.3 Micro-Burr Formation 2188.6.4 Process Conditions Optimization 2198.7 Application Perspectives 2208.8 Concluding Remarks 220References 2219 Micro Drilling Applications 227M. J. Jackson, T. Novakov and K. Mosiman9.1 Chapter Overview 2279.2 Investigation of Chatter in Mesoscale Drilling 2279.2.1 Torsional-axial Model 2319.2.2 Bending Model 2399.2.3 Combination of the Bending and Torsional-axial Models 2429.2.4 Chatter Suppression 2519.2.5 Research Challenges 2569.3 Investigation of Chatter in Micro Drilling 2579.4 Case Study: Micro Drilling Medical Polymer Materials and Composites 2659.4.1 Tooling Selection 2669.4.2 Cutting Mechanisms and Considerations 2679.4.3 Drilling 2689.4.4 Burr Elimination when Drilling Polymers 2699.5 Conclusions 270Acknowledgements 271References 27210 Micro Grinding Applications 275Han Huang10.1 Introduction 27510.2 Principles and Methodologies 27810.2.1 Removal Mechanism in the Grinding of Brittle Materials 27810.2.2 Interaction Between a Work Material and Diamond Abrasives 28010.2.3 Grinding Approaches for Micro Grinding 28510.3 Implementation Perspectives 28610.3.1 Truing and Dressing 28610.3.2 Characterization of Wheel Topography and Cutting Edge Distribution 28710.3.3 Measurement of Grit Height Distribution 29110.3.4 Characterization of Abrasive Wear 29210.3.5 Compensation Grinding 29210.3.6 Pragmatic Aspects in Profile Grinding 29710.3.7 Parametric Effects in Profile Grinding 29810.4 Application Cases 29910.4.1 Micro Grinding of Aspherical Moulds 29910.4.2 Micro Grinding of Optical Fibre Connectors 305Acknowledgements 311References 31111 In-Process Micro/Nano Measurement for Micro Cutting 315Wei Gao, Kang-Won Lee, Young-Jin Noh, Yoshikazu Arai and Yuki Shimizu11.1 Introduction 31511.2 The Hybrid Instrument for Micro Cutting and In-process Measurement 31611.3 In-process Measurement of Micro Cutting Force 32611.4 In-process Measurement of Micro Wear of Cutting Tool 33111.5 In-process Measurement of Micro Surface Form 33711.6 Summary 342References 343Index 345