Nowadays technology development places increasing demands on miniature and micro components and products, and micro-milling is one of the most flexible machining processes in manufacturing 3D structures and complex structured surfaces. A thorough and scientific understanding on fundamentals of the micro-milling process is essential for applying it in an industrial scale. Therefore, in-depth scientific understanding of the micro-cutting mechanics is critical, particularly on size effect, minimum chip thickness, chip formation, tool wear and cutting temperature, etc. so as to fulfil the gap between fundamentals and industrial scale applications. Therefore, three key fundamental research topics are determined for this research, and a comprehensive study on those topics is conducted by means of modeling, simulation, experiments. The topics include chip formation process in micro-milling, novel cutting force modeling in multiscale and study on the tool wear and process monitoring. The investigation into chip formation process in micro-milling consists of three stages; the micro-cutting process is firstly simulated by means of FEA with a primary focus on finding the minimum chip thickness for different tool/material pair and explaining the size effect; the simulation results are then validated by conducting micro-cutting experiment on the ultra-precision lathe. Experiments are carried out on aluminium 6082-T6 with both natural diamond and tungsten carbide tool. By knowing the minimum chip thickness for different tool/material pair, the chip formation process is investigated by performing comparative study by using the diamond and tungsten carbide micro-milling tools. As the minimum chip thickness for diamond micro-milling tool is smaller than that for tungsten carbide tool compared to nominal chip thickness, MCT is ignored in diamond micro-milling. Thus the comparative study is conducted by utilizing both tools with perfectly sharpened cutting edge and tools with the rounded cutting edge in micro-milling. The chips are inspected and associated with cutting force variations in the micro-milling process. The findings are further consolidated by comparing with research results by other researchers. The cutting force modeling is developed in three different aspects, e.g. cutting force on the unit length or area and cutting force on the unit volume in order to better understand the micro-cutting mechanics in aspects of size effect, tool wear mechanism and the cutting energy consumption. The mathematical modeling firstly starts with a novel instantaneous chip thickness algorithm, in which the instantaneous chip thickness is computed by taking account of the change of tool geometry brought about by the tool runout; then the collected cutting forces are utilized to calibrate the model coefficients. For accurate measurement on cutting forces, the Kalman Filter technique is employed to compensate the distortion of the measured cutting force. Model calibration is implemented using least-square method. The proposed cutting force model is then applied in micro-milling to represent the conditions of tool wear and the cutting energy consumption. Further study on the surface generation simulation is based on force model and its comparison with the machined surface is also performed. Cutting experiments using the new tungsten carbide tool are carried out and the tool wear is monitored offline at different machining stages. The dominant tool wear types are characterised. Tool wear is investigated by mainly analysing cutting force at different tool wear status. Frequency analysis by Fourier Transform and Wavelet Transform are carried out on the force signals, and features closely related to the tool wear status are identified and extracted. The potential of applying these features to monitoring the tool wear process is then discussed. Experimental studies to machine the structured surface and nano-metric level surface roughness are presented, the machining efficiency, dimensional accuracy and tool-path strategies are optimised so as to achieve the desired outcomes. Moreover, investigation on cutting temperature in micro-cutting is also studied to some extent by means of simulation; the influence of cutting edge radius on cutting temperature is particularly investigated. Investigation on above aspects provides systematic exploration into the micro-milling process and can contribute substantially to future micro-milling applications.

During machining play the size off component deciding role from the viewpoint of their behaviour. This is result of „size effect”, which turns common characteristic cutting process. The aim of diploma thesis was contribute piece of knowledge verification of this effect and the further exploit during machining. The main interest is directed to the relation between the cutting edge and depth of cut.

The paper proposes a method for characterizing the in-situ interaction between filaments in a multifilament yarn. The stress transfer between neighboring filaments causes the reactivation of a broken filament at some distance from the break. The utilized statistical bundle models predict a change in the slope of the mean size effect curve once the specimen length becomes longer than the stress transfer length. This fact can be exploited in order to determine the stress transfer length indirectly using the yarn tensile test with appropriately chosen test lengths. The identification procedure is demonstrated using two test series of tensile tests with AR-glass and carbon yarns.

Des simulations de dynamique de dislocation (DD) sont utilisées pour l’étude de l'effet Hall-Petch (HP) et des contraintes internes à long-portée induites par les hétérogénéités de déformation dans les matériaux polycristallins.L'effet HP est reproduit avec succès grâce à des simulations de DD réalisées sur de simples agrégats polycristallins périodiques composés de 1 ou de 4 grains. De plus, l'influence de la forme des grains a été explorée en simulant des grains avec différents rapports d'aspect. Une loi généralisée de HP est proposée pour quantifier l'influence de la morphologie du grain en définissant une taille de grain effective. La valeur moyenne de la constante HP $K$ calculée avec différentes orientations cristallines à faible déformation est proche des valeurs expérimentales.Les dislocations stockées pendant la déformation sont principalement localisées à proximité des joints de grain et peuvent être traitées comme une distribution surfacique de dislocations. Nous avons utilisé des simulations DD pour calculer les contraintes associées aux parois de dislocations de différentes hauteurs, longueurs densités et caractères. Dans tous les cas, la contrainte est proportionnelle à la densité surfacique de dislocations géométriquement nécessaires (GNDs) et sa variation est capturée par un ensemble d'équations empiriques simples. Une prévision de contraintes à long-portée dans les grains est réalisée en sommant les contributions des GNDs accumulées de part et d’autre des joints de grains.L'augmentation de la contrainte interne liée au stockage de GNDs est linéaire avec la déformation plastique et est indépendante de la taille des grains. L'effet de taille observé dans les simulations de DD est attribué au seuil de déformation plastique, contrôlé par deux mécanismes concurrents : la contrainte critique de multiplication des sources et la contrainte critique de franchissement de la forêt. En raison de la localisation de la déformation dans les matériaux à gros grains, le modèle d’empilement des dislocations doit être utilisé pour prédire la contrainte critique dans ce cas. En superposant cette propriété aux analyses que nous avons fait à partir de simulations de DD dans le cas d'une déformation homogène, l'effet HP est justifié pour une large gamme de tailles de grains. / Dislocation Dynamics (DD) simulations are used to investigate the Hall-Petch (HP) effect and back stresses induced by grain boundaries (GB) in polycrystalline materials.The HP effect is successfully reproduced with DD simulations in simple periodic polycrystalline aggregates composed of 1 or 4 grains. In addition, the influence of grain shape was explored by simulating grains with different aspect ratios. A generalized HP law is proposed to quantify the influence of the grain morphology by defining an effective grain size. The average value of the HP constant K calculated with different crystal orientations at low strain is close to the experimental values.The dislocations stored during deformation are mainly located at GB and can be dealt with as a surface distribution of Geometrically Necessary Dislocations (GNDs). We used DD simulations to compute the back stresses induced by finite dislocation walls of different height, width, density and character. In all cases, back stresses are found proportional to the surface density and their spatial variations can be captured using a set of simple empirical equations. The back stress calculation inside grains is achieved by adding the contributions of GNDs accumulated at each GB facet.These back stresses are found to increase linearly with plastic strain and are independent of the grain size. The observed size effect in DD simulations is attributed to the threshold of plastic deformation, controlled by two competing mechanisms: the activation of dislocation sources and forest strengthening. Due to strain localization in coarse-grained materials, the pile-up model is used to predict the critical stress. By superposing such property to the analysis we made from DD simulations in the case of homogeneous deformation, the HP effect is justified for a wide range of grain sizes.

La fatigue de contact fait référence au processus d’endommagement situé à l’extrémité du contact entre deux corps soumis à des chargements de fatigue. La prédiction de ce phénomène est d’une importance majeure dans la détermination de la durée de vie de certains systèmes tels que les disques de turbines. Au voisinage du front de contact, le champ de contraintes est maximal en surface et présente un fort gradient sous le contact. De plus, la différence d’échelle entre les essais effectués en laboratoire et les systèmes industriels a motivé l’étude de l’effet de taille sur les modèles de fatigue des systèmes soumis à des chargements de fatigue du contact.Afin de quantifier l’effet de gradient de contraintes et l’effet de taille, des essais ont été effectués sur une machine de fatigue munis de deux vérins verticaux à l’université de Brasilia. Les essais ont été menés de sorte que les gradients de contraintes, puis les volumes contraints, soient différents. Une étude post-mortem des surfaces de rupture a été effectuée à l’aide d’un microscope confocal. Durant cette thèse, il a été montré que, pour un alliage de Ti-6Al-4v, une approche non locale basée sur un champ de vitesse équivalent extrait à l’intérieur d’une zone prédéterminée autour de l’extrémité du contact amène des résultats encourageants pour la détermination de la durée de vie. L’influence de la force de fatigue sur la description des mécanismes d’initiation de fissures et leur propagation a également été déterminée et il est apparu que cette dernière ne pouvait pas être négligée lors de la définition de la frontière d’initiation des fissures. En effet, si, en fatigue du contact, environ 75% du mécanisme d’initiation des fissures est contrôlé par les contraintes de contact, i.e. les contraintes de cisaillement et de pression, la prise en compte de la contrainte normale permet d’obtenir des prédictions plus précises.L’étude de l’effet de taille a été divisée en deux phases. Premièrement, l’influence de la taille du volume sous contrainte a été analysée. Pour cela, l’épaisseur des éprouvettes a été réduite tandis que le gradient de contraintes sous le contact ainsi que l’aire de la surface endommagée étaient maintenus constants. Dans un second temps, l’impact de la zone endommagée sur la résistance à la fatigue a été isolé en maintenant les paramètres expérimentaux, i.e. σB,max/p0 et Q/fP, constants tandis que l’aire endommagée par le frottements était réduite. Les résultats expérimentaux ont été analysés à l’aide d’un critère de fatigue multiaxial, le Courbe de Wöhler Modifiée, conjointement avec l’application de la théorie de la distance critique. Il a été montré qu’aucun de ces deux paramètres n’influence significativement la durée de vie en fatigue, et ainsi le terme « effet de taille » généralement référencé dans la littérature comme un effet d’endommagement devrait seulement être adressé comme un effet de gradient. / Fretting fatigue refers to the damage process localized at the frontier of the contact between two contacting bodies subjected to fatigue loadings. The prediction of this phenomenon is of major importance in determining, for instance, the lifetime of fan’s disk. In the vicinity of the contact front, the stress field inherited from the contact loads is maximal at the surface and displays a strong gradient under the contact. The difference of scale between the laboratory’s experiments and the industrials’ system motivated the study of the impact of the size effect for the determination of the lifetimes.To quantify the effect of the stress gradient and of the size effect, tests were carried out on a two vertical-actuators fretting-fatigue rig at the University of Brasilia, with experimental conditions ensuring different stress gradient and later different volume solicited under the contact. Damage mechanisms were studied using post-mortem analysis with a confocal microscope on some contact elements tested.It was shown on this thesis, for a Ti-6Al-4V alloy, that a nonlocal approach, based on equivalent velocity field on a determined area around the contact, leads to good expectation for the determination of fretting fatigue lives. The influence of the bulk stress for the description of the fretting fatigue crack initiation and propagation was also determined and it appears that it could not be neglected for the determination of the crack initiation boundary. As a matter of fact, if around 75% of the crack initiation mechanism in fretting fatigue is controlled by the contact stresses, i.e. shear and contact stresses, the consideration of the normal stress allows to obtain more realistic prediction. The study of the size effect was divided into two phases. First the influence of the volume stressed was investigated by reducing the width of the contact but maintaining the stress gradient under the contact and the damaged area within the slip zone constant. Then, the influence of the damaged area within the slip zone was isolated by maintaining the experimental parameters, i.e. σB,max/p0 and Q/fP, constant while the damaged area under the slip zone was reduced. The experimental results were analysed by applying a fatigue criterion, the Modified Wöhler Curve Method, in conjunction with the Theory of the Critical Distance. It was found that none of these two parameters influences significantly the fretting fatigue lifetimes, and so the term ‘size effect’ usually referenced in the literature as a damaging effect should refer only to the gradient effect.

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第20336号 / 工博第4273号 / 新制||工||1662(附属図書館) / 京都大学大学院工学研究科材料工学専攻 / (主査)教授 辻 伸泰, 教授 松原 英一郎, 教授 乾 晴行 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

Surface and grain boundary electron scattering contribute significantly to resistivity as the dimensions of polycrystalline metallic conductors are reduced to, and below, the electron mean free path. A quantitative measurement of the relative contributions of surface and grain boundary scattering to resistivity is very challenging, requiring not only the preparation of suitably small conductors having independent variation of the two relevant length scales, namely, the sample critical dimension and the grain size, but also independent experimental quantification of these two length scales. In most work to date the sample grain size has been either assumed equal to conductor dimension or measured for only a small number of grains. Thus, the quantification of the classical size effect still suffers from an uncertainty in the relative contributions of surface and grain boundary scattering. In this work, a quantitative analysis of both surface and grain boundary scattering in Cu thin films with independent variation of film thickness (27 nm to 158 nm) and grain size (35 nm to 425 nm) in samples prepared by sub-ambient temperature film deposition followed by annealing is reported. Film resistivities of carefully characterized samples were measured at both room temperature and at 4.2 K and were compared with several scattering models that include the effects of surface and grain boundary scattering. Grain boundary scattering is found to provide the strongest contribution to the resistivity increase. However, a weaker, but significant, role is also observed for surface scattering. Several of the published models for grain boundary and surface scattering are explored and the Matthiessen's rule combination of the Mayadas and Shatzkes' model of grain boundary scattering and Fuchs and Sondheimer's model of surface scattering resistivity contributions is found to be most appropriate. It is found that the experimental data are best described by a grain boundary reflection coefficient of 0.43 and a surface specularity coefficient of 0.52. This analysis finds a significantly lower contribution from surface scattering than has been reported in previous works, which is in part due to the careful quantitative microstructural characterization of samples performed. The data does suggest that there is a roughness dependence to the surface scattering, but this was not conclusively demonstrated. Voids and impurities were found to have negligible impact on the measured resistivities of the carefully prepared films.

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