Abstract

The analysis of the high-speed mechanical micromilling process is described in this chapter. The present work not only compares computational approaches to the solution of shear plane and tool face temperatures, but also explains why there is a difference when calculating temperatures generated during the micromachining process. The analysis shows that the computed temperature of the shear plane never exceeds 35°C when micromilling at spindle speeds approximately 310,000 rpm. Machining AISI 1040 steel at significantly high speeds presents significant challenges to prevent the accelerated wear of the cutting tool that is caused by the frictional interactions between chip and tool and the nature of the intermittent contact. The analysis also shows the effect of coating at reducing the interface temperatures between chip and tool, and concludes that each coating has very little effect at reducing temperature at the tool face and at the primary shear zone. The results shown here are reported in Ref. 11. Reprinted with kind permission from Springer Science + Business Media B.V. © 2015 Elsevier Inc. All rights reserved.