Modelling the cutting edge radius size effect for force prediction in micro milling

CIRP Annals ◽  
2008 ◽  
Vol 57 (1) ◽  
pp. 113-116 ◽  
Author(s):  
G. Bissacco ◽  
H.N. Hansen ◽  
J. Slunsky
Keyword(s):  
Size Effect ◽  
Cutting Edge ◽  
Micro Milling ◽  
Force Prediction ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Radius Size

scholarly journals An Improved Cutting Force Model in Micro-milling Considering the Comprehensive Effect of Tool Runout, Size Effect and Tool Wear

2021 ◽  
Author(s):  
Tongshun Liu ◽  
Yayun Liu ◽  
Kedong Zhang
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Cutting Force ◽  
Cutting Edge ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Tool Runout ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract Tool runout, cutting edge radius-size effect and tool wear have significant impacts on the cutting force of micro-milling. In order to predict the micro-milling force and the machining performance related to the cutting force, it is necessary to establish a cutting force model including tool runout, cutting edge radius and tool wear. In this study, an instantaneous uncut thickness (IUCT) model considering tool runout, a nonlinear shear/ploughing coefficient model including cutting-edge radius and a friction force coefficient model embedded with flank wear width, are constructed respectively. By integrating the IUCT, the nonlinear shear/ploughing coefficient and the friction force coefficient, a comprehensive micromilling force model including the tool runout, size effect and tool wear is derived. Experiment results show that the proposed comprehensive model is efficient to predict the micro milling force.

Development of Cutting Edge Radius Size of Solid Carbide Mills When Drag Finishing

2020 ◽  
pp. 95-100
Author(s):  
Boris Pätoprstý ◽  
Marek Vozár ◽  
Peter Pokorný ◽  
Tomáš Vopát ◽  
Ivan Buranský ◽  
...  
Keyword(s):  
Cutting Edge ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Solid Carbide ◽  
Drag Finishing ◽  
Radius Size

scholarly journals Investigation of the Effect of End Mill-Geometry on Roughness and Surface Strain-Hardening of Aluminum Alloy AA6082

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3078
Author(s):  
Pavel Filippov ◽  
Michael Kaufeld ◽  
Martin Ebner ◽  
Ursula Koch
Keyword(s):  
Surface Roughness ◽  
Strain Hardening ◽  
Cutting Edge ◽  
Surface Strain ◽  
Micro Milling ◽  
End Mill ◽  
Cutting Edge Radius ◽  
Hardened Zone ◽  
Edge Radius ◽  
Machined Surfaces

Micro-milling is a promising technology for micro-manufacturing of high-tech components. A deep understanding of the micro-milling process is necessary since a simple downscaling from conventional milling is impossible. In this study, the effect of the mill geometry and feed per tooth on roughness and indentation hardness of micro-machined AA6082 surfaces is analyzed. A solid carbide (SC) single-tooth end-mill (cutting edge radius 670 nm) is compared to a monocrystalline diamond (MD) end-mill (cutting edge radius 17 nm). Feed per tooth was varied by 3 μm, 8 μm and 14 μm. The machined surface roughness was analyzed microscopically, while surface strain-hardening was determined using an indentation procedure with multiple partial unload cycles. No significant feed per tooth influence on surface roughness or mechanical properties was observed within the chosen range. Tools’ cutting edge roughness is demonstrated to be the main factor influencing the surface roughness. The SC-tool machined surfaces had an average Rq = 119 nm, while the MD-tool machined surfaces reached Rq = 26 nm. Surface strain-hardening is influenced mainly by the cutting edge radius (size-effect). For surfaces produced with the SC-tool, depth of the strain-hardened zone is higher than 200 nm and the hardness increases up to 160% compared to bulk. MD-tool produced a thinner strain-hardened zone of max. 60 nm while the hardness increased up to 125% at the surface. These findings are especially important for the high-precision manufacturing of measurement technology modules for the terahertz range.

Investigation of Size Effect on Micro Hardness of Machined Surface in Micro Cutting

2014 ◽  
Vol 602-605 ◽  
pp. 443-446
Author(s):  
Tao Zhang ◽  
Zhen Yu Shi ◽  
Bing Yan ◽  
Hou Jun Qi
Keyword(s):  
Size Effect ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Three Dimension ◽  
Micro Hardness ◽  
Uncut Chip Thickness ◽  
Machined Surface ◽  
Micro Cutting ◽  
Cutting Edge Radius ◽  
Edge Radius

Micro cutting is a promising way for manufacturing micro parts, especially micro three dimension parts. Micro hardness is an important character to evaluate surface integrity of machined surface. Micro cutting is different from macro cutting due to size effect of specific cutting energy because of the influence of the ratio of uncut chip thickness to cutting edge radius. A group of micro cutting experiments were conducted to investigate the cutting parameters on the micro hardness of machined surface. The micro hardness of machines surface decreases with the ratio of uncut chip thickness to cutting edge radius first, and then increase when the uncut chip thickness is smaller than the cutting edge radius. The micro hardness shows size effect due to the machined surface compressed twice with the round cutting edge. The micro hardness decreases with the distance increasing far away from the machined surface.

A Finite Element Analysis of Micro/Meso-Scale Machining Considering the Cutting Edge Radius

2007 ◽  
Vol 10-12 ◽  
pp. 631-636 ◽  
Author(s):  
Zi Yang Cao ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Finite Element ◽  
Stress Field ◽  
Size Effect ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Cutting Process ◽  
Plastic Deformation Zone ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Meso Scale

In order to investigate the effects of cutting edge radius on micro/meso-scale cutting process, the current paper is concerned with a fundamental investigation of the contribution of cutting edge radius to cutting temperature, stress field and size effect by means of two-dimensional finite-element simulation for orthogonal cutting process. The results indicated that cutting edge radius has remarkable effects on cutting temperature and stress field, and the existence of cutting edge radius is one of the main reasons generating size effect. The cutting edge radius affects the micro/meso scale cutting process at smaller uncut chip thickness by altering the effective rake angle and enhancing the plowing effect, affecting the material deformation process, expanding and widening the plastic deformation zone, and causing higher energy dissipation due to increased tool-chip contact length.

Effects of Tool Nose Corner Radius and Main Cutting-Edge Radius on Cutting Temperature in Micro-Milling Inconel 718 Process

2017 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Likun Si ◽  
Steven Y. Liang
Keyword(s):  
Three Dimensional ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Milling Cutter ◽  
Micro Scale ◽  
Cutting Edge Radius ◽  
Corner Radius ◽  
Edge Radius

Cutting temperature plays an important role in micro-scale cutting process because the dimension of the micro-milling cutter is relatively small and the wear of micro-milling cutter is sensitive to temperature. Considering the sidewall of a groove is formed by main cutting edge of the tool, and the bottom of a groove is formed by tool tip and the edge on the end of the tool. Therefore, effects of tool nose corner radius and main cutting edge radius on cutting temperature in micro-milling process cannot be ignored. However, few studies have been conducted on this issue. The effects of tool nose corner radius and main cutting edge radius on cutting temperature is investigated. A three-dimensional micro-milling Inconel718 model is established by using the software DEFORM3D. And the influence of tool nose corner radius and main cutting edge radius on the size and distribution of cutting temperature are studied by numerical simulation, which is verified by experiments. The work provide reference for the control of the size and distribution of the cutting temperature during micro-milling process.

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