Research On Micro-cutting Process Of Oxygen-free Copper Through Simulation And Experiment

Micro cutting is a kind of important machining method used for manufacturingmicro-nano structure of materials or products. Due to micron level characteristicparameters of micro cutting machining, using this machining method can achievehigher machining precision, higher surface quality and smaller surface damage.However, the characteristic parameter is very small, so the size effect of micro cuttingprocess should not be neglected, and mechanism of chip formation is essentialdifference between the micro-cutting and the traditional cutting. For the traditionalcutting, the cutting depth is larger, tool tip radius on the edge is relatively smallcompared with cutting depth, therefore, the cutting tool is generally assumedabsolutely sharp, the influence of cutting tool tip is ignored on cutting process. Inmicro cutting, cutting depth is often only a few microns, in this case, the influence ofthe cutting tool edge radius need to be considered. Therefore, in order to better usemicro cutting technology, researching on mechanism of micro cutting is of greatsignificance.This paper comprehensively analyzed the researching status about micro cuttingat home and abroad, introduced the current mainstream method of simulation formicro cutting, analyzed the superiorities and defects of these methods, at the sametime, reviewed the researching status of micro cutting experiment. In basis ofcombining the domestic and foreign research on micro cutting, this paper used a newmethod to study the mechanism of micro cutting through simulation. Using thismethod analyzed the mechanism of chip formation in micro cutting processconsidering the Oxygen-free Copper as the workpiece, the minimum cutting depthwas researched and analyzed, and then the influence factors on cutting force in the micro cutting process were discussed, and further discussed residual stressdistribution in machining surface after cutting process, and sequential cuts was usedto study the influence of residual stresses on minimum cutting depth and cutting force.Considering the content of the simulation and the purpose of study in this paper, theoverall scheme of the micro cutting test system is designed, three-dimensionalmodeling software Catia was used to establish the three-dimensional model of themachine, using of the finite element software Ansys made the statics analysis andmodal analysis for each unit and the machine. Based on this, the micro cutting testplatform is developed, made the calibration and analysis for the designedtwo-dimension force sensor, then the experiment has been carried on to study theoutput characteristics of the precision control unit. Finally, a series of micro cuttingexperiment was carried out by using the developed micro cutting test platform.In this article, the mechanism of micro machining of oxygen free copper wasexplained through the simulation analysis method, and the simulation results areverified by experiments. Simulation results showed that the minimum cutting depth is0.15times of cutting tool edge radius, experiment shows that the minimum cuttingdepth is0.172times of cutting tool edge radius. There is a certain error between thesimulation results and the experimental results. The reason for error is the differenceof friction coefficient between the simulation and experiment.