Instantaneous uncut chip thickness modeling for micro-end milling process

2017 ◽  
Vol 21 (4) ◽  
pp. 582-602 ◽  
Author(s):  
Xuewei Zhang ◽  
Tianbiao Yu ◽  
Wanshan Wang
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Uncut Chip Thickness ◽  
Micro End Milling ◽  
Instantaneous Uncut Chip Thickness ◽  
End Milling Process

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.

A New Method for Identifying the Cutter Runout Parameters in Flat End Milling Process

2011 ◽  
Vol 697-698 ◽  
pp. 71-74 ◽  
Author(s):  
Min Wan ◽  
M.S. Lu ◽  
Wei Hong Zhang ◽  
Y. Yang ◽  
Y. Li
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Least Square Method ◽  
Noise Signal ◽  
Milling Process ◽  
Least Square ◽  
Cutter Runout ◽  
Flat End Milling ◽  
Instantaneous Uncut Chip Thickness ◽  
End Milling Process

Cutter runout will redistribute the instantaneous uncut chip thickness and the cutting forces in multi-fluted milling process. In this paper, a new procedure is proposed to identify the cutter runout parameters for flat end milling process. By combining least-square method, mathematical derivations and implementation procedures are carried out based on the relative deviation between each cutting edge and the spindle rotation center, measured by a dial gauge. Numerical verifications are conducted to validate the proposed procedures, and the results show that they are efficient and reliable. It is also suggested that to weaken the influence of noise signal, measurements should be conducted at multiple axial positions.

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.

Instantaneous Uncut Chip Thickness Model in End Milling Based on an Improved Method

2018 ◽  
Vol 764 ◽  
pp. 399-407
Author(s):  
Yue Zhang ◽  
Zhi Qiang Yu ◽  
Tai Yong Wang
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Transcendental Equation ◽  
Milling Process ◽  
Force Model ◽  
Uncut Chip Thickness ◽  
Milling Force ◽  
Milling Force Model ◽  
Instantaneous Uncut Chip Thickness ◽  
Taylor’S Series

The instantaneous uncut chip thickness is an important parameter in the study of milling force model. By analyzing the real tooth trajectory in milling process, accurate instantaneous uncut chip thickness can be obtained to solve the complex transcendental equation. Traditional chip thickness models always simplify the tooth trajectory to get approximate solution. A new instantaneous uncut chip thickness model is proposed in this paper. Based on real tooth trajectory of general end milling cutter, a Taylor's series is used to approximate the involved infinitesimal variable in the transcendental equation, which results in an explicit expression for practical application of the uncut chip thickness with higher accuracy compared to the traditional model.

An Experimental Investigation of Cutting Forces in Micro End-Milling Process

2016 ◽  
Vol 693 ◽  
pp. 710-717
Author(s):  
Yan Jie Yuan ◽  
Xiu Bing Jing ◽  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Milling Process ◽  
Resultant Force ◽  
Feed Force ◽  
Micro End Milling ◽  
End Milling Process ◽  
Shear Energy

This paper presents an experimental study of cutting forces during micro end-milling of brass. The influences of cutting speed and feed per tooth on cutting forces have been researched. The results show that the resultant force Fr and feed force Fx significantly increase with increasing the feed per tooth. The resultant force Fr, feed force Fxand normal force Fy increase with increasing cutting speed. The specific shear energy is also investigated. It is observed that the specific shear energy increases greatly with decreasing the feed per tooth when the feed per tooth is less than minimum chip thickness.

Experimental Study on Micro End-Milling Process of Ti-6AL-4V Using Nanofluid Minimum Quantity Lubrication (MQL)

2014 ◽  
Author(s):  
Dae Hoon Kim ◽  
Pil-Ho Lee ◽  
Jung Sub Kim ◽  
Hyungpil Moon ◽  
Sang Won Lee
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nanofluid Minimum Quantity Lubrication ◽  
Micro End Milling ◽  
Milling Forces ◽  
End Milling Process

This paper investigates the characteristics of micro end-milling process of titanium alloy (Ti-6AL-4V) using nanofluid minimum quantity lubrication (MQL). A series of micro end-milling experiments are conducted in the meso-scale machine tool system, and milling forces, burr formations, surface roughness, and tool wear are observed and analyzed according to varying feed per tooth and lubrication conditions. The experimental results show that MQL and nanofluid MQL with nanodiamond particles can be effective to reduce milling forces, burrs and surface roughness during micro end-milling of titanium alloy. In particular, it is demonstrated that smaller size of nanodiamond particles — 35 nm — can be more effective to decrease burrs and surface roughness in the case of nanofluid MQL micro end-milling.

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