scholarly journals Modelling and experimental analysis of the effects of run out, minimum chip thickness and elastic recovery on the cutting force in micro-end-milling

2020 ◽  
Vol 176 ◽  
pp. 105540 ◽  
Author(s):  
Xiubing Jing ◽  
Rongyu Lv ◽  
Yun Chen ◽  
Yanling Tian ◽  
Huaizhong Li
Keyword(s):  
Cutting Force ◽  
Experimental Analysis ◽  
End Milling ◽  
Elastic Recovery ◽  
Chip Thickness ◽  
Minimum Chip Thickness ◽  
Micro End Milling

Dynamic cutting force prediction for micro end milling considering tool vibrations and run-out

2018 ◽  
Vol 233 (7) ◽  
pp. 2248-2261 ◽  
Author(s):  
Xuewei Zhang ◽  
Tianbiao Yu ◽  
Wanshan Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Dynamic Cutting Force ◽  
Micro End Milling ◽  
Tool Vibrations ◽  
End Milling Process

An accurate prediction of cutting forces in the micro end milling, which is affected by many factors, is the basis for increasing the machining productivity and selecting optimal cutting parameters. This paper develops a dynamic cutting force model in the micro end milling taking into account tool vibrations and run-out. The influence of tool run-out is integrated with the trochoidal trajectory of tooth and the size effect of cutting edge radius into the static undeformed chip thickness. Meanwhile, the real-time tool vibrations are obtained from differential motion equations with the measured modal parameters, in which the process damping effect is superposed as feedback on the undeformed chip thickness. The proposed dynamic cutting force model has been experimentally validated in the micro end milling process of the Al6061 workpiece. The tool run-out parameters and cutting forces coefficients can be identified on the basis of the measured cutting forces. Compared with the traditional model without tool vibrations and run-out, the predicted and measured cutting forces in the micro end milling process show closer agreement when considering tool vibrations and run-out.

Investigation of the Dynamics of Microend Milling—Part II: Model Validation and Interpretation

2006 ◽  
Vol 128 (4) ◽  
pp. 901-912 ◽  
Author(s):  
Martin B. G. Jun ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Dynamic Model ◽  
End Milling ◽  
Elastic Recovery ◽  
Chip Thickness ◽  
Thickness Effect ◽  
Depth Of Cut ◽  
Minimum Chip Thickness ◽  
Microend Milling ◽  
The Stability ◽  
Cutting Mechanisms

In Part II of this paper, experimental and analytical methods have been developed to estimate the values of the process faults defined in Part I of this paper. The additional faults introduced by the microend mill design are shown to have a significant influence on the total net runout of the microend mill. The dynamic model has been validated through microend milling experiments. Using the dynamic model, the effects of minimum chip thickness and elastic recovery on microend milling stability have been studied over a range of feed rates for which the cutting mechanisms vary from ploughing-dominated to shearing-dominated. The minimum chip thickness effect is found to cause feed rate dependent instability at low feed rates, and the range of unstable feed rates depends on the axial depth of cut. The effects of process faults on microend mill vibrations have also been studied and the influence of the unbalance from the faults is found to be significant as spindle speed is increased. The stability characteristics due to the regenerative effect have been studied. The results show that the stability lobes from the second mode of the microend mill, which are generally neglected in macroscale end milling, affect the microend mill stability significantly.

A Study on Cutting Force in Micro End Milling with Ultrasonic Vibration

2010 ◽  
Vol 97-101 ◽  
pp. 1910-1914 ◽  
Author(s):  
Xue Hui Shen ◽  
Jian Hua Zhang ◽  
Tian Jin Yin ◽  
Chun Jie Dong
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
End Milling ◽  
Chip Thickness ◽  
Normal Direction ◽  
Micro Milling ◽  
Short Service Life ◽  
Micro Parts ◽  
Micro End Milling ◽  
Cutting Effect

The applications of micro end milling have been gradually broadened to meet the ever-increasing demands for micro parts. In micro milling, premature tool failure and short service life are major problems. In this study, micro end milling with ultrasonic vibration in normal direction is investigated. Kinematical analysis is done to describe the exact trajectory of the tool tip when vibration is applied. Based on which, an analytical model of chip formation is proposed. By accurate calculation of instantaneous chip thickness, the cutting forces in micro end milling with and without ultrasonic vibration are predicted and verified by a slot-milling experiment. As a result, it is found that ultrasonic vibration in normal direction is helpful when reducing the cutting force owing to intermittent cutting effect.

Cutting Force Analysis to Determine the Performance of Micro End Milling Process of Silicon Wafer

2007 ◽  
Author(s):  
Rusnaldy ◽  
Tae Jo Ko ◽  
Hee Sool Kim
Keyword(s):  
Cutting Force ◽  
Silicon Wafer ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Tool Material ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Micro End Milling

There is a lack of fundamental understanding of micro-end-milling of silicon wafer, specifically basic understanding of material removal mechanism, cutting forces and machined surface integrity in micro scale machining of silicon. It is necessary to determine the forces generated during the cutting operation due to chip thickness along with tool geometry, tool material properties and workpiece properties because cutting forces will provide vital information for the design, modeling and control of the machining process. In this study, cutting force data can be used to determine cutting regime machining of silicon wafer.

Modeling and Experimental Analysis the Effect of Minimum Chip Thickness on Cutting Temperature in Micro-End-Milling Process

2010 ◽  
Vol 102-104 ◽  
pp. 506-510 ◽  
Author(s):  
Ying Chun Liang ◽  
Kai Yang ◽  
Qing Shun Bai ◽  
W.Q. Chen
Keyword(s):  
Aluminum Alloy ◽  
End Milling ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Milling Process ◽  
Depth Of Cut ◽  
Minimum Chip Thickness ◽  
Micro End Milling ◽  
Simulation Results ◽  
End Milling Process

In this paper, the effect of minimum chip thickness on cutting temperature in micro-end- milling of aluminum alloy Al2024-T6 using a tungsten-carbide cutter are investigated and analyzed. The three-dimensional coupled thermal-mechanical finite element model is adopted to determine the effects of varying depth of cut on cutting temperature considering size effects. The simulation results show that the cutting temperature in micro-end-milling is lower than those occurring in conventional milling processes. When the depth of cut is approximately 40% of the cutting edge radius, there is no chip formation. The maximum temperature occurs at the contact region between micro cutting edge and workpiece, which shows an obvious size effect. The experimental verification of the simulation model is carried out on a micro-end-milling process of aluminum alloy 2024-T6 with a high precision infrared camera. The influence of various cutting depths on cutting temperature has been verified in experiments. The experimental measurements results are in a good agreement with the simulation results.

Effect of circular tool path on cutting force profile in micro-end-milling

2011 ◽  
Vol 226 (6) ◽  
pp. 1589-1600 ◽  
Author(s):  
A Banerjee ◽  
E V Bordatchev
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Tool Path ◽  
End Milling ◽  
Chip Thickness ◽  
Micro Milling ◽  
Tool Paths ◽  
Chip Formation Mechanism ◽  
Micro End Milling ◽  
Lower Tool

Micro-end-milling requires high spindle rotational speed to achieve effective material removal. This results in the requirement of tool stoppage or slowdown during a micro-end-milling operation, a deterrent to productivity and to part acceptability. A circular tool path geometry can avoid discontinuities in the tool movements leading to a more consistent and smooth material removal. However, optimal process planning for such a tool path will require detailed understanding of the chip-formation mechanism in circular end-milling. The cut geometry during end-milling along a circular tool path is often approximated as that of a linear tool path. Although this assumption works well for circular tool paths with higher tool path radius, this is not the case for lower tool path radius often used in micro-milling. In this study, the effect of circular tool path on the cutting force for varying tool path rotation angle, tool path radius, and feed rate is experimentally investigated. Systematic signal processing was applied to analyse the measured cutting force signal along linear and several circular tool paths. Qualitative as well as quantitative differences were observed in the cutting force profiles obtained using different tool path radii, tool path orientations, and feed rates. This implies the need for an improved chip thickness formulation dedicated to micro-end-milling with circular tool path rather than approximating it with formulations derived for linear tool path.

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