Geometrical Simulation of Chip Production Rate in Micro-EndMilling

Jue Hyun Lee, Angela A. Sodemann

Research output: Contribution to journalConference articlepeer-review

5 Scopus citations


In conventional-scale machining, the mechanics of the tool-workpiece interface are dominated by shearing. But, in micro-machining, the mechanics of the tool-workpiece interface are affected also by ploughing and elasto-plastic workpiece deformation, due to the minimum chip thickness effect as the minimum chip thickness becomes comparable to the uncut chip thickness. Especially, the ploughing effect increases cutting forces resulting in poor surface integrity and burr formation. A clear understanding of the relationships between shearing, ploughing, and elasto-plastic deformation is required to manage these effects. Here, we propose that the chip production rate is an indicator of the state of the interaction at the tool-workpiece interface. In this paper, the influence of the minimum chip thickness effect is investigated by a geometrical simulation of the chip production rate due to the varying uncut chip thickness, less than or above the minimum chip thickness in micro-endmilling. The chip production rate is predicted by counting the number of chips generated by the intermittent engagement of the cutting tooth based on the trochoidal path. The simulation results predict as much as 50% reduction and 200% increase in the chip production rate at a certain chip volume range as the uncut chip thickness becomes smaller than minimum chip thickness assuming that the cutting edge radius is constant.

Original languageEnglish (US)
Pages (from-to)209-216
Number of pages8
JournalProcedia Manufacturing
StatePublished - 2018
Event46th SME North American Manufacturing Research Conference, NAMRC 2018 - College Station, United States
Duration: Jun 18 2018Jun 22 2018


  • Chip production rate
  • Micro-endmill
  • Minimum chip thickness
  • Ploughing effect

ASJC Scopus subject areas

  • Artificial Intelligence
  • Industrial and Manufacturing Engineering


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