A new method for determining the instantaneous uncut chip thickness in micro-milling

2019 ◽  
Vol 102 (9-12) ◽  
pp. 3791-3800 ◽  
Author(s):  
Xiang Zhang ◽  
Xudong Pan ◽  
Guanglin Wang
Keyword(s):  
Chip Thickness ◽  
New Method ◽  
Micro Milling ◽  
Uncut Chip Thickness ◽  
Instantaneous Uncut Chip Thickness

scholarly journals Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model

Micromachines ◽  
2021 ◽  
Vol 12 (12) ◽  
pp. 1495
Author(s):  
Tongshun Liu ◽  
Kedong Zhang ◽  
Gang Wang ◽  
Chengdong Wang
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Uncut Chip Thickness ◽  
Milling Force ◽  
Minimum Uncut Chip Thickness ◽  
Cutting Force Coefficient ◽  
Milling Force Model

The minimum uncut chip thickness (MUCT), dividing the cutting zone into the shear region and the ploughing region, has a strong nonlinear effect on the cutting force of micro-milling. Determining the MUCT value is fundamental in order to predict the micro-milling force. In this study, based on the assumption that the normal shear force and the normal ploughing force are equivalent at the MUCT point, a novel analytical MUCT model considering the comprehensive effect of shear stress, friction angle, ploughing coefficient and cutting-edge radius is constructed to determine the MUCT. Nonlinear piecewise cutting force coefficient functions with the novel MUCT as the break point are constructed to represent the distribution of the shear/ploughing force under the effect of the minimum uncut chip thickness. By integrating the cutting force coefficient function, the nonlinear micro-milling force is predicted. Theoretical analysis shows that the nonlinear cutting force coefficient function embedded with the novel MUCT is absolutely integrable, making the micro-milling force model more stable and accurate than the conventional models. Moreover, by considering different factors in the MUCT model, the proposed micro-milling force model is more flexible than the traditional models. Micro-milling experiments under different cutting conditions have verified the efficiency and improvement of the proposed micro-milling force model.

An accurate instantaneous uncut chip thickness model combining runout effect in micro-milling using cutters with the non-uniform helix and pitch angles

2019 ◽  
Vol 234 (5) ◽  
pp. 859-870 ◽  
Author(s):  
Qiang Guo ◽  
Yan Jiang ◽  
Zhibo Yang ◽  
Fei Yan
Keyword(s):  
Tool Path ◽  
Chip Thickness ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Cutter Runout ◽  
Model Combining ◽  
Key Factor ◽  
Cutting Point ◽  
Instantaneous Uncut Chip Thickness

As a key factor, the accuracy of the instantaneous undeformed thickness model determines the force-predicting precision and further affects workpiece machining precision in the micro-milling process. The runout with five parameters affects the machining process more significantly compared with macro-milling. Furthermore, modern industry uses cutters with non-uniform pitch and helix angles more and more common for their excellent properties. In this article, an instantaneous undeformed thickness model is presented regarding cutter runout, variable pitch, and helix angles in the micro-milling process. The cutter edge with the cutter runout effect is modeled. Then, the intersecting ellipse between the plane vertical to the spindle axis and the cutter surface which is a cylinder can be gained. Based on this, the points, which are used to remove the material, on the ellipse as well as cutter edges are calculated. The true trochoid trajectory for each cutting point along the tool path is built. Finally, the instantaneous undeformed thickness values are computed using a numerical algorithm. In addition, this article analyzes runout parameters’ effects on the instantaneous undeformed thickness values. After that, helix and pitch angles’ effects on the instantaneous undeformed thickness are studied. Ultimately, the last section verifies the correctness and validity of the instantaneous undeformed thickness model based on the experiment conducted in the literature.

Chip Thickness Analysis in Peripheral Milling of Curved Surfaces with Variable Curvature Considering Cutter Runout

2011 ◽  
Vol 697-698 ◽  
pp. 75-79 ◽  
Author(s):  
Y. Yang ◽  
Min Wan ◽  
Wei Hong Zhang ◽  
Y. Li
Keyword(s):  
Chip Thickness ◽  
Current Approach ◽  
The Novel ◽  
Cutter Runout ◽  
Peripheral Milling ◽  
Uncut Chip Thickness ◽  
Systematic Analysis ◽  
Variable Curvature ◽  
Proposed Model ◽  
Instantaneous Uncut Chip Thickness

Analysis of instantaneous uncut chip thickness (IUCT) in peripheral milling of curved surface with variable curvature is nontrivial due to the combined influences of both process geometry and cutter runout. This paper gives a systematic analysis of IUCT including the effects of changing workpiece geometry and the cutter runout in peripheral milling. The prominent feature of this analysis procedure lies in that the novel equation for computing the IUCT is mathematically derived in detail. Numerical simulations are performed to study the effect of workpiece curvature and cutter runout on IUCT. The proposed model is validated by comparing the measured cutting forces with those predicted based on the IUCT which is obtained using the current approach.

Single Edge Cutting Phenomenon and Instantaneous Uncut Chip Thickness Model of Micro-Ball-End Milling

2011 ◽  
Vol 4 (4) ◽  
pp. 1387-1393 ◽  
Author(s):  
Zhenyu Han ◽  
Xiang Zhang ◽  
Yazhou Sun ◽  
Hongya Fu ◽  
Yingchun Liang
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Single Edge ◽  
Uncut Chip Thickness ◽  
Ball End Milling ◽  
Instantaneous Uncut Chip Thickness

scholarly journals Cutting Forces in Peripheral Up-Milling of Particleboard

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2208
Author(s):  
Bartosz Pałubicki
Keyword(s):  
Cutting Forces ◽  
Thrust Force ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Solid Wood ◽  
Numerical Control ◽  
Single Chip ◽  
Uncut Chip Thickness ◽  
Force Signal ◽  
Instantaneous Uncut Chip Thickness

An analysis of forces acting in the peripheral up-milling of particleboard is presented. First, a novel method of high-frequency piezoelectric force signal treatment is proposed and used to separate the original force signal from the vibrations of the previous cutting iteration. This allows for the analysis of single chip cutting force courses during industrial CNC (Computer Numerical Control) milling. The acting forces are compared with the theoretical, instantaneous, uncut chip thickness. The results show that, for a range of 40–60 m/s, the higher the cutting speed used, the higher the resultant and principal cutting forces. The method of cutting thrust force used was similar to that observed in solid wood milling, i.e., first using a pushing action, followed by a pulling action. The obtained average specific principal cutting forces for particleboard peripheral up-milling are equal to 32.0 N/mm2 for slow and 37.6 N/mm2 for fast milling. The specific cutting thrust force decreases with the increase in instantaneous uncut chip thickness.

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