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A comparative study of material phase effects on micro-machinability of multiphase materials

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Abstract

In the mechanical micro-machining of multiphase materials, the cutting process is undertaken at a length scale where material heterogeneity has to be considered. This has led to increasing interest in optimising the process parameters for micro-machining of such materials. In this study the micro-machinability of two steels, a predominantly ferrite material (AISI 1005) and a near-balanced ferrite/pearlite microstructure (AISI 1045) was studied. Workpiece sample deformation properties were characterised by nano-indentation testing. Additionally, metallographic grain size evaluation was undertaken for the workpiece microstructures. Surface roughness, workpiece microstructure and burr size for micro-machined parts as well as tool wear were examined over a range of feed rates. The results suggest that for micro-machined parts, differential elastic recovery between phases leads to higher surface roughness when the surface quality of micro-machined multiphase phase material is compared to that of single phase material. On the other hand, for single phase predominantly ferritic materials, reducing burr size and tool wear are major challenges. Thus, the paper elucidates on material property effects on surface and workpiece edge quality during micro-milling.

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Authors and Affiliations

  1. Manufacturing and Laser Processing Group, School of Mechanical, Aerospace and Civil Engineering, The University of Manchester, M60 1QD, Manchester, UK

    Aamer J. Mian, Nicholas Driver & Paul T. Mativenga

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  1. Aamer J. Mian
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  2. Nicholas Driver
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  3. Paul T. Mativenga
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Correspondence to Aamer J. Mian.

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Mian, A.J., Driver, N. & Mativenga, P.T. A comparative study of material phase effects on micro-machinability of multiphase materials. Int J Adv Manuf Technol 50, 163–174 (2010). https://doi.org/10.1007/s00170-009-2506-9

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  • DOI: https://doi.org/10.1007/s00170-009-2506-9

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