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.

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.

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.

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.

Micro Flat End Milling Simulation Model With Instantaneous Plowing Area Prediction

2016 ◽  
Vol 4 (2) ◽  
Author(s):  
Abdolreza Bayesteh ◽  
Junghyuk Ko ◽  
Martin Byung-Guk Jun
Keyword(s):  
Feed Rate ◽  
Tool Path ◽  
End Milling ◽  
Chip Thickness ◽  
Depth Of Cut ◽  
Uncut Chip Thickness ◽  
Chip Area ◽  
Edge Radius ◽  
Wide Range ◽  
Radial Depth

There is an increasing demand for product miniaturization and parts with features as low as few microns. Micromilling is one of the promising methods to fabricate miniature parts in a wide range of sectors including biomedical, electronic, and aerospace. Due to the large edge radius relative to uncut chip thickness, plowing is a dominant cutting mechanism in micromilling for low feed rates and has adverse effects on the surface quality, and thus, for a given tool path, it is important to be able to predict the amount of plowing. This paper presents a new method to calculate plowing volume for a given tool path in micromilling. For an incremental feed rate movement of a micro end mill along a given tool path, the uncut chip thickness at a given feed rate is determined, and based on the minimum chip thickness value compared to the uncut chip thickness, the areas of plowing and shearing are calculated. The workpiece is represented by a dual-Dexel model, and the simulation properties are initialized with real cutting parameters. During real-time simulation, the plowed volume is calculated using the algorithm developed. The simulated chip area results are qualitatively compared with measured resultant forces for verification of the model and using the model, effects of cutting conditions such as feed rate, edge radius, and radial depth of cut on the amount of shearing and plowing are investigated.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

scholarly journals Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model

Micromachines ◽  
2021 ◽  
Vol 12 (12) ◽  
pp. 1495
Author(s):  
Tongshun Liu ◽  
Kedong Zhang ◽  
Gang Wang ◽  
Chengdong Wang
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Uncut Chip Thickness ◽  
Milling Force ◽  
Minimum Uncut Chip Thickness ◽  
Cutting Force Coefficient ◽  
Milling Force Model

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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