Simulation And Surface Roughness Prediction Study Of Single Crystal Copper Micro-milling

The demand for single crystal copper micro-components is increasing in various fields currently,because single crystal copper has good electrical conductivity.Micro-milling technology is a kind of processing and manufacturing technology that combines traditional mechanical technology with numerical control and precision machining.It can process a variety of materials,has high processing precision,and can process 3D parts with complex geometric features.Micro-milling technology is an effective processing technology for small single crystal copper parts.However,there is no research report on micro-milling of single crystal copper.Therefore,this paper studies the micro-milling process and surface roughness prediction of single crystal copper.The specific research contents are as follows:Based on the crystal plastic constitutive equation,the VUMAT constitutive subroutine of single crystal copper material was programmed.The model of micro-milling tool and workpiece was established and meshed.Then the single crystal copper micro-milling process simulation model was established considering the friction between the tool and the workpiece and material removal.The effectiveness of the finite element simulation model of single crystal copper micro-milling process was verified by comparing the experimentally measured cutting force with the cutting force of the simulated output.The orthogonal experimental study on the surface roughness of micro-milling of different crystal orientation single crystal copper was conducted.The influence of cutting parameters on surface roughness was analyzed by range analysis.The surface roughness of single crystal copper micro-milling in different crystal orientations was predicted by SVM method.The experimental results show that the average relative error of surface roughness of <100>,<110>,<111> crystal orientation single crystal copper is 2.7%,3.3%,2.2%,and the maximum relative error is 7.0%.10.1%,2.8%,respectively.The established surface roughness prediction model has higher prediction accuracy.Finally,the uncertainty analysis is carried out by Monte Carlo method to verify the reliability of the model.In this paper,the micro-milling process of single crystal copper is explored.And the cutting process is studied.Then the surface roughness of single crystal copper micro-milling is studied based on the orthogonal test.The exploratory research results of micro-milling of single crystal copper are provides a reference on micro-milling of single crystal materials.