Z.Y. Shi and Z.Q. Liu

Abstract: In micromachining, when the undeformed chip thickness becomes comparable to the edge radius of the cutting tool, the effective rake angle becomes to be negative and has significant effect on the determination of the minimum uncut chip thickness. The determination of the minimum uncut chip thickness is essential in micro machining in order to achieve desired surface integrity and accuracy. In this paper, an Arbitrary Lagrangian Eulerian (ALE)-based numerical modeling is proposed to determine the minimum uncut chip thickness for Copper by changing the cutting tool's nominal rake angle. According to the relationship between the minimum uncut chip thickness and the effective rake angle, a mathematical model that reflects the relationship between the effective rake angle and the nominal rake angle is established.