Development of micro milling force model and cutting parameter optimization

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.

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Coupled thermal and mechanical analyses of micro-milling Inconel 718

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405418774586 ◽

2018 ◽

Vol 233 (4) ◽

pp. 1112-1126 ◽

Cited By ~ 10

Author(s):

Xiaohong Lu ◽

Hua Wang ◽

Zhenyuan Jia ◽

Yixuan Feng ◽

Steven Y Liang

Keyword(s):

Inconel 718 ◽

Cutting Temperature ◽

Milling Process ◽

Micro Milling ◽

Force Model ◽

Temperature Model ◽

Milling Force ◽

Mechanical Coupling ◽

Milling Forces ◽

Milling Force Model

Micro-milling forces, cutting temperature, and thermal–mechanical coupling are the key research topics about the mechanism of micro-milling nickel-based superalloy Inconel 718. Most current analyses of thermal–mechanical coupling in micro-milling are based on finite element or experimental methods. The simulation is not conducive to revealing the micro-milling mechanism, while the results of experiments are only valid for certain machine tool and workpiece material. Few analytical coupling models of cutting force and cutting temperature during micro-milling process have been proposed. Therefore, the authors studied coupled thermal–mechanical analyses of micro-milling Inconel 718 and presented a revised three-dimensional analytical model of micro-milling forces, which considers the effects of the cutting temperature and the ploughing force caused by the arc of cutting edge during shear-dominant cutting process. Then, an analytical cutting temperature model based on Fourier’s law is presented by regarding the contact area as a moving finite-length heat source. Coupling calculation between micro-milling force model and temperature model through an iterative process is conducted. The novelty is including cutting temperature into micro-milling force model, which simulates the interaction between cutting force and cutting temperature during micro-milling process. The established model predicts both micro-milling force and temperature. Finally, experiments are conducted to verify the accuracy of the proposed analytical method. Based on the coupled thermal–mechanical analyses and experimental results, the authors reveal the effects of cutting parameters on micro-milling forces and temperature.

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A Comprehensive Micro-milling Force Model for A Low-stiffness Machining System

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4051005 ◽

2021 ◽

pp. 1-42

Author(s):

Da Qu ◽

Bo Wang ◽

Yuan Gao ◽

Huajun Cao

Keyword(s):

Chip Thickness ◽

Micro Milling ◽

Force Model ◽

Milling Force ◽

Undeformed Chip Thickness ◽

Single Tooth ◽

Good Prediction Accuracy ◽

Low Stiffness ◽

Milling Force Model ◽

Tooth Cutting

Abstract Micro-milling is widely used in various crucial fields with the ability of machining micro- and meso-scaled functional structures on various materials efficiently. However, the micro-milling force model is not comprehensively developed yet when tool feature sizes continually decrease to under two hundred microns in a low-stiffness system. This paper proposes an analytical force model considering the influence of tool radius, size effect, tool runout, tool deflection, and the actual trochoidal trajectories and the interaction of historical tool teeth trajectories (IHTTT). Different micro-milling status are recognized by analyzing the cutting process of different tool teeth. Conditions of single-tooth cutting status are determined by a proposed numerical algorithm, and entry angle and exit angle are analyzed under various cutting conditions for the low-stiffness system. Three micro-milling status, including single-tooth cutting status, are distinguished based on the instantaneous undeformed chip thickness resulting in three types of material removal mechanisms in predicting micro-milling force components. Discontinuous change rates of undeformed chip thickness are found in the low-stiffness micro-milling system. The proposed micro-milling force model is then verified through experiments of micro slot milling Elgiloy alloy with a 150-µm-diametrical two-teeth micro-end-mill. The experimental results show a Root-Mean-Square Error (RSME) of 0.092 N in the predicted resultant force, accounting for approximately 5.12% of the measured force, by which the proposed theoretical model is verified to be of good prediction accuracy.

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Energy efficient cutting parameter optimization

Frontiers of Mechanical Engineering ◽

10.1007/s11465-020-0627-x ◽

2021 ◽

Author(s):

Xingzheng Chen ◽

Congbo Li ◽

Ying Tang ◽

Li Li ◽

Hongcheng Li

Keyword(s):

Energy Efficiency ◽

Energy Consumption ◽

Parameter Optimization ◽

Energy Efficient ◽

Cutting Parameters ◽

Machining Process ◽

Cutting Fluid ◽

Current Status ◽

Cutting Parameter ◽

Cutting Parameter Optimization

AbstractMechanical manufacturing industry consumes substantial energy with low energy efficiency. Increasing pressures from energy price and environmental directive force mechanical manufacturing industries to implement energy efficient technologies for reducing energy consumption and improving energy efficiency of their machining processes. In a practical machining process, cutting parameters are vital variables set by manufacturers in accordance with machining requirements of workpiece and machining condition. Proper selection of cutting parameters with energy consideration can effectively reduce energy consumption and improve energy efficiency of the machining process. Over the past 10 years, many researchers have been engaged in energy efficient cutting parameter optimization, and a large amount of literature have been published. This paper conducts a comprehensive literature review of current studies on energy efficient cutting parameter optimization to fully understand the recent advances in this research area. The energy consumption characteristics of machining process are analyzed by decomposing total energy consumption into electrical energy consumption of machine tool and embodied energy of cutting tool and cutting fluid. Current studies on energy efficient cutting parameter optimization by using experimental design method and energy models are reviewed in a comprehensive manner. Combined with the current status, future research directions of energy efficient cutting parameter optimization are presented.

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Milling force model for asymmetric end-mills during high-feed milling on AISI-P20

Materials and Manufacturing Processes ◽

10.1080/10426914.2021.1944199 ◽

2021 ◽

pp. 1-8

Author(s):

Diego Russo ◽

Gorka Urbicain ◽

Antonio J. Sánchez Egea ◽

Alejandro Simoncelli ◽

Daniel Martinez Krahmer

Keyword(s):

Force Model ◽

Milling Force ◽

Aisi P20 ◽

High Feed ◽

End Mills ◽

Milling Force Model

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Multi-objective cutting parameter optimization model of multi-pass turning in CNC machines for sustainable manufacturing

Heliyon ◽

10.1016/j.heliyon.2021.e06043 ◽

2021 ◽

Vol 7 (2) ◽

pp. e06043 ◽

Cited By ~ 1

Author(s):

Phengky Pangestu ◽

Eko Pujiyanto ◽

Cucuk Nur Rosyidi

Keyword(s):

Parameter Optimization ◽

Optimization Model ◽

Sustainable Manufacturing ◽

Cnc Machines ◽

Cutting Parameter ◽

Multi Objective ◽

Cutting Parameter Optimization

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Milling force model prediction considering tool runout with three-teeth alternating disc cutter

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-021-06949-z ◽

2021 ◽

Author(s):

Yang Cheng ◽

Shi Yaoyao ◽

Xin Hongmin ◽

Zhang Nan

Keyword(s):

Model Prediction ◽

Disc Cutter ◽

Force Model ◽

Milling Force ◽

Tool Runout ◽

Milling Force Model

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A New Method for the Prediction of Micro-Milling Tool Breakage

Volume 1: Processes ◽

10.1115/msec2017-2999 ◽

2017 ◽

Cited By ~ 1

Author(s):

Xiaohong Lu ◽

Haixing Zhang ◽

Zhenyuan Jia ◽

Yixuan Feng ◽

Steven Y. Liang

Keyword(s):

Cutting Parameters ◽

Ultimate Stress ◽

New Method ◽

Micro Milling ◽

Force Model ◽

Bending Stress ◽

Tool Breakage ◽

Parameters Selection ◽

Milling Tool ◽

Milling Force Model

Micro-milling tool breakage has become a bottleneck for the development of micro-milling technology. A new method to predict micro-milling tool breakage based on theoretical model is presented in this paper. Based on the previously built micro-milling force model, the bending stress of the micro-milling cutter caused by the distributed load along the spiral cutting edge is calculated; Then, the ultimate stress of carbide micro-milling tool is obtained by experiments; Finally, the bending stress at the dangerous part of the micro-milling tool is compared with the ultimate stress. Tool breakage curves are drawn with feed per tooth and axial cutting depth as horizontal and vertical axes respectively. The area above the curve is the tool breakage zone, and the area below the curve is the safety zone. The research provides a new method for the prediction of micro-milling tool breakage, and therefore guides the cutting parameters selection in micro-milling.

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