Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials

The cutting mechanism and residual stress profile of the micro-cutting thin workpiece are affected by the interaction of the thin workpiece and the fixture (substrate) underneath it similar to that observed in the nano-indentation and nano-scratching of thin film. The appropriate substrate propertie...

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Main Authors: Saptaji, Kushendarsyah, Subbiah, Sathyan
Format: Conference or Workshop Item
Language:English
English
Published: IOP Publishing 2016
Subjects:
Online Access:http://umpir.ump.edu.my/id/eprint/11329/1/iMEC_2015__APCOMS_2015_submission_18.pdf
http://umpir.ump.edu.my/id/eprint/11329/7/fkp-saptaji-2016-Finite%20Element%20Study%20of%20the%20Effect%20of%20Substrate%20Properties.pdf
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author Saptaji, Kushendarsyah
Subbiah, Sathyan
author_facet Saptaji, Kushendarsyah
Subbiah, Sathyan
author_sort Saptaji, Kushendarsyah
collection UMP
description The cutting mechanism and residual stress profile of the micro-cutting thin workpiece are affected by the interaction of the thin workpiece and the fixture (substrate) underneath it similar to that observed in the nano-indentation and nano-scratching of thin film. The appropriate substrate properties are necessary especially to avoid detachment during machining and to minimize deformation and warping of the machined thin workpiece. Thus, the investigations of the influence of substrate properties on micro-cutting thin workpiece are essentially to be conducted. The finite element study of orthogonal micro-cutting of thin Al6061-T6 is presented here. The simulations were conducted to study the residual stress profile across the thickness of the machined thin workpiece at various workpiece thicknesses and various substrate (adhesive) elastic properties. Simulations results show that as the machined workpiece become thinner, the stress is more significant not only on the machined surface but also it can reach the bottom of the workpiece. The stiffer substrate produces less variation of the stress across the workpiece thickness while more compliant substrate produces broader stress variation as the workpiece become thinner. The results show the significant effect of the workpiece thickness and the substrate properties on the stress profiles in the micro-cutting of thin workpiece.
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spelling UMPir113292018-02-23T07:18:30Z http://umpir.ump.edu.my/id/eprint/11329/ Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials Saptaji, Kushendarsyah Subbiah, Sathyan TJ Mechanical engineering and machinery TS Manufactures The cutting mechanism and residual stress profile of the micro-cutting thin workpiece are affected by the interaction of the thin workpiece and the fixture (substrate) underneath it similar to that observed in the nano-indentation and nano-scratching of thin film. The appropriate substrate properties are necessary especially to avoid detachment during machining and to minimize deformation and warping of the machined thin workpiece. Thus, the investigations of the influence of substrate properties on micro-cutting thin workpiece are essentially to be conducted. The finite element study of orthogonal micro-cutting of thin Al6061-T6 is presented here. The simulations were conducted to study the residual stress profile across the thickness of the machined thin workpiece at various workpiece thicknesses and various substrate (adhesive) elastic properties. Simulations results show that as the machined workpiece become thinner, the stress is more significant not only on the machined surface but also it can reach the bottom of the workpiece. The stiffer substrate produces less variation of the stress across the workpiece thickness while more compliant substrate produces broader stress variation as the workpiece become thinner. The results show the significant effect of the workpiece thickness and the substrate properties on the stress profiles in the micro-cutting of thin workpiece. IOP Publishing 2016 Conference or Workshop Item PeerReviewed application/pdf en http://umpir.ump.edu.my/id/eprint/11329/1/iMEC_2015__APCOMS_2015_submission_18.pdf application/pdf en cc_by http://umpir.ump.edu.my/id/eprint/11329/7/fkp-saptaji-2016-Finite%20Element%20Study%20of%20the%20Effect%20of%20Substrate%20Properties.pdf Saptaji, Kushendarsyah and Subbiah, Sathyan (2016) Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials. In: IOP Conference Series: Materials Science and Engineering: 2nd International Manufacturing Engineering Conference and 3rd Asia-Pacific Conference on Manufacturing Systems (iMEC-APCOMS 2015) , 12–14 November 2015 , Kuala Lumpur, Malaysia. pp. 1-11., 114 (012005). (Published) http://dx.doi.org/10.1088/1757-899X/114/1/012005
spellingShingle TJ Mechanical engineering and machinery
TS Manufactures
Saptaji, Kushendarsyah
Subbiah, Sathyan
Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials
title Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials
title_full Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials
title_fullStr Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials
title_full_unstemmed Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials
title_short Finite Element Study on The Effect of Substrate Properties in Micro-cutting Thin Workpiece Materials
title_sort finite element study on the effect of substrate properties in micro cutting thin workpiece materials
topic TJ Mechanical engineering and machinery
TS Manufactures
url http://umpir.ump.edu.my/id/eprint/11329/1/iMEC_2015__APCOMS_2015_submission_18.pdf
http://umpir.ump.edu.my/id/eprint/11329/7/fkp-saptaji-2016-Finite%20Element%20Study%20of%20the%20Effect%20of%20Substrate%20Properties.pdf
work_keys_str_mv AT saptajikushendarsyah finiteelementstudyontheeffectofsubstratepropertiesinmicrocuttingthinworkpiecematerials
AT subbiahsathyan finiteelementstudyontheeffectofsubstratepropertiesinmicrocuttingthinworkpiecematerials