Abstract
Mechanical micromachining is an alternative to standard methods of microfabrication owing to its applicability to a wide range of materials, cost, and versatility of the process. Many approaches have been undertaken to understand the behavior on such a small scale including experimental work, finite element analysis (FEA), molecular dynamics simulations (MD) as well as closed-form analytical approaches. The purpose of the present study investigated the use of Third Wave Systems’ AdvantEdge™ Lagrangian-Eulerian formulated FEA software to analyze chip and non-chip formation when micromachining Ti6Al4V titanium alloy for medical device applications. For the specific machining conditions described in this paper, chip formation occurred when cutting force (F C)/thrust force (F T) > 1 and burr formation occurred when F C/F T < 1. In addition to the force conditions, when the ratio of feed per tooth to tool edge radius is approximately unity (f tooth/t r ~ 1), the micromachining process forms chips. When the ratio it decreased equal to 0.5 (f tooth/t r = 0.5), chip formation and burr formation exist simultaneously. However, when the ratio approaches an approximate value of 0.3 (f tooth/t r ~ 0.3), burr formation is dominant. The paper focuses on understanding the mechanisms of chip formation as a way to preserve the integrity of the surfaces of medical materials.
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Jackson, M.J., Novakov, T., da Silva, M.B. et al. Predicting chip and non-chip formation when micromachining Ti-6Al-4V titanium alloy. Int J Adv Manuf Technol 91, 955–985 (2017). https://doi.org/10.1007/s00170-016-9754-2
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DOI: https://doi.org/10.1007/s00170-016-9754-2