Investigation of Cutting Edge Radius Effect in Macro-machining and Micro-machining

Chip formation is a dynamic process that is often nonlinear in nature. A chip may not form when the depth of cut is less than a minimum chip thickness. This paper presents an investigation of cutting edge radius effect in macro- and micro-machining of AISI D2 steel via simulation using ABAQUS software. Through the arbitrary Lagrangian–Eulerian FE modeling approach, the chip growth, chip formation, and cutting force were investigated under three criteria such as a/r 1, and a/r = 1. The results from this simulation can provide useful information for choosing reasonable cutting edge to improve surface integrity and prolong cutting tool life in macro- and micro-milling operation. It is found that the chip is formed at a/r > 1 while material extrusion performed under a/r < 1. The investigation on the cutting force found that value of a/r ratios greatly affects the cutting force. The cutting mechanism in micro-milling is similar to macro-milling due to the process undergoes both ploughing and shearing mechanism.