Development of Micro Milling Machine and Experimental Study on Meso Scale Milling

2007 ◽  
Author(s):  
Chengfeng Li ◽  
Xinmin Lai ◽  
Hongtao Li ◽  
Linfa Peng ◽  
Jun Ni
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Three Dimensional ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Micro Milling ◽  
Milling Machine ◽  
Meso Scale

This paper develops a three-axis micro milling machine for manufacturing meso-scale components and products. This machine utilizes high-speed miniature spindle to obtain appropriate cutting velocities, and three precision linear stages with 50 nm feed resolution to supply the relative motion. The PMAC2 controller is used to control three axes simultaneously, and a piezoelectric dynamometer is mounted on the X-Y stages to measure three-dimensional cutting forces for the real-time measurement and feedback. More than 200 cutting experiments of end milling operations are performed on the developed machine. When the machined feature ranges at meso scale, the characteristics and phenomena in milling process will heavily differ from those of conventional scale milling due to the size effects. The critical differences at meso scale arise from the breakdown of the assumptions of negligible edge radius effects. The roundness of cutting edge and the runout of spindle have a crucial impact on the chip formation process and the characteristics of cutting forces. The roundness of cutting edge also induces the existence of the minimum chip thickness and the intermittency of the chip formation at a low feed per tooth.

Design and Testing of a Micro-Dynamometer for Desktop Micro-Milling Machine

2014 ◽  
Vol 902 ◽  
pp. 267-273 ◽  
Author(s):  
Samir Mekid
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
High Speed ◽  
High Surface ◽  
Chip Thickness ◽  
Micro Milling ◽  
High Tech ◽  
Machining Accuracy ◽  
Microscopic Features ◽  
Better Than

The emerging miniaturized high-tech products are required to have increased functionalities of systems within a volumetric size on the order of 1 cm3. Hence, the parts are mesoscopic with complex microscopic features of a few mm length with machining accuracy of better than 1 micrometer with secured surface integrity as components will require high surface finish, tensile stress and crack free surfaces in order to function reliably. One of the characteristics to be measured is the cutting forces on the parts being machined. This paper will present the design, manufacture and testing of a miniature dynamometer capable of measuring cutting forces within a low range of 50N but with a resolution better than 1 mN and high frequency since the micromachining involves small cutting forces but the spindle rotates at high speed. The dynamometer is capable of measuring forces in five directions (±x, ±y, and z). The instrument was calibrated and exhibit very good results leading to a true validation. This instrument is assembled on a micro milling desktop machine designed in-house. It will not only support predicting the surface finish and chip thickness but also monitoring tool wear evolution and hence prevents/reduce tool breakage known to be one of the main issues in micro-milling.

An Approach to Modeling Cutting Forces in Five-Axis Ball-End Milling of Curved Geometries Based on Tool Motion Analysis

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Guo Dongming ◽  
Ren Fei ◽  
Sun Yuwen
Keyword(s):  
Motion Analysis ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Axis Orientation ◽  
Undeformed Chip Thickness ◽  
Ball End Milling ◽  
Tool Motion ◽  
Five Axis

The prediction of five-axis ball-end milling forces is quite a challenge due to difficulties of determining the underformed chip thickness and engaged cutting edge. To solve these concerns, this paper presents a new mechanistic model of cutting forces based on tool motion analysis. In the model, for undeformed chip thickness determination, an analytical model is first established to describe the sweep surface of cutting edge during the five-axis ball-end milling process of curved geometries. The undeformed chip thickness is then calculated according to the real kinematic trajectory of cutting edges under continuous change of the cutter axis orientation. A Z-map method is used to verify the engaged cutting edge and cutting coefficients are subsequently calibrated. The mechanistic method is applied to predict the cutting force. Validation tests are conducted under different cutter postures and cutting conditions. The comparison between predicted and measured values demonstrates the applicability of the proposed prediction model of cutting forces.

CUTTING FORCES ANALYSIS IN WHIRLING PROCESS

2010 ◽  
Vol 24 (15n16) ◽  
pp. 2786-2791 ◽  
Author(s):  
JAE HWAN SON ◽  
CHANG WOO HAN ◽  
SUN IL KIM ◽  
HEE CHUL JUNG ◽  
YOUNG MOON LEE
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
Adams Software ◽  
Rotating Workpiece ◽  
Cutting Experiments

Whirling is a cutting process in which a series of cutting edges remove material by turning over the rotating workpiece. In this process, the whirling ring with a number of cutting teeth combined with the rotation and advancement of workpiece, produces pitches of worm. Mechanics of chip formation of the process, however, has not been fully estabilished. To estimate the cutting force during the process, the kinematics and the maximum undeformed chip thickness to be removed by each cutting edge should be thoroughly analyzed. In this study, using the recently developed model of undeformed chip thickness and the DEFORM software, cutting forces of the whirling process are estimated. The effects of cutting forces on tool are analyzed using the ADAMS software. The validity of the simulations has been verified with a series of cutting experiments.

Model of the instantaneous undeformed chip thickness in micro-milling based on tooth trajectory

2016 ◽  
Vol 232 (2) ◽  
pp. 226-239 ◽  
Author(s):  
Xiaohong Lu ◽  
Zhenyuan Jia ◽  
Furui Wang ◽  
Guangjun Li ◽  
Likun Si ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Chip Thickness ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Undeformed Chip Thickness ◽  
Single Tooth ◽  
Extended Length ◽  
Manufacturing Errors ◽  
Tooth Cutting

Instantaneous undeformed chip thickness is one of the key parameters in modeling of micro-milling process. Most of the existing instantaneous undeformed chip thickness models in meso-scale cutting process are based on the trochoidal trajectory of the cutting edge, which neglect the influences of cutter installation errors, cutter-holder manufacturing errors, radial runout of the spindle and so forth on the instantaneous undeformed chip thickness. This article investigates the tooth trajectory in micro-milling process. A prediction model of radial runout of cutting edge is built, with consideration of the effects of the extended length of micro-milling cutter and the spindle speed. Considering the effects of cutting-edge trochoidal trajectory, radial runout of cutting edge and the minimum cutting thickness, a novel instantaneous undeformed chip thickness model is proposed, and the phenomenon of single-tooth cutting in micro-milling process is analyzed. Comparisons of cutting forces under different chip thickness models and experimental data indicate that this new model can be used to predict cutting forces.

Cutting edge wear in high-speed stainless steel end milling

2021 ◽  
Author(s):  
Mohammad Malekan ◽  
Camilla D. Bloch-Jensen ◽  
Maryam Alizadeh Zolbin ◽  
Klaus B. Ørskov ◽  
Henrik M. Jensen ◽  
...  
Keyword(s):  
Stainless Steel ◽  
High Speed ◽  
End Milling ◽  
Cutting Edge ◽  
Edge Wear

Voxel Based Cutting Force Simulation of Ball End Milling Considering Cutting Edge Around Center Web

2018 ◽  
Author(s):  
Isamu Nishida ◽  
Takaya Nakamura ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Chip Thickness ◽  
Previous Method ◽  
Cutting Edge ◽  
Force Model ◽  
End Mill ◽  
Uncut Chip Thickness ◽  
Ball End Mill ◽  
Tool Rotation

A new method, which accurately predicts cutting force in ball end milling considering cutting edge around center web, has been proposed. The new method accurately calculates the uncut chip thickness, which is required to estimate the cutting force by the instantaneous rigid force model. In the instantaneous rigid force model, the uncut chip thickness is generally calculated on the cutting edge in each minute disk element piled up along the tool axis. However, the orientation of tool cutting edge of ball end mill is different from that of square end mill. Therefore, for the ball end mill, the uncut chip thickness cannot be calculated accurately in the minute disk element, especially around the center web. Then, this study proposes a method to calculate the uncut chip thickness along the vector connecting the center of the ball and the cutting edge. The proposed method can reduce the estimation error of the uncut chip thickness especially around the center web compared with the previous method. Our study also realizes to calculate the uncut chip thickness discretely by using voxel model and detecting the removal voxels in each minute tool rotation angle, in which the relative relationship between a cutting edge and a workpiece, which changes dynamically during tool rotation. A cutting experiment with the ball end mill was conducted in order to validate the proposed method. The results showed that the error between the measured and predicted cutting forces can be reduced by the proposed method compared with the previous method.

scholarly journals Stability analysis for a single-point cutting tool deflection in turning operation

2019 ◽  
Vol 11 (6) ◽  
pp. 168781401985318
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Beam Model ◽  
Tool Deflection

In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.

scholarly journals Analysis of chip formation and cutting forces in end milling AISI D2 tool steel with different cutting tool geometries

2018 ◽  
Vol 178 ◽  
pp. 01016
Author(s):  
Irina Beşliu ◽  
Dumitru Amarandei ◽  
Delia Cerlincă
Keyword(s):  
Cutting Force ◽  
Tool Steel ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Tool ◽  
End Milling ◽  
Great Influence ◽  
Tool Geometry ◽  
Aisi D2 ◽  
Aisi D2 Tool Steel

The purpose of this study was to investigate and establish the correlations between milling tool geometry, cutting conditions, as input factors and the cutting forces variations and chips formation, as output factors when end milling of AISI D2 tool steel. The experiments were carried out using a Taguchi design array. The chip shape and microstructure and cutting force components were analyzed. The results of the study show that the cutting tool geometry has a great influence over segmented chip formation mechanism and cutting force levels.

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