The Dynamic Analysis of Micro-Scale Edge in the Process of Micromilling

2013 ◽  
Vol 797 ◽  
pp. 628-637
Author(s):  
Ya Dong Gong ◽  
Jin Feng Zhang ◽  
Jun Cheng ◽  
Xue Long Wen ◽  
Chao Wang ◽  
...  
Keyword(s):  
Fourier Method ◽  
Milling Process ◽  
Spindle Speed ◽  
Micro Milling ◽  
Theoretical Research ◽  
Actual Case ◽  
Micro Scale ◽  
Machined Parts ◽  
Micro Tool ◽  
Milling Chatter

The micro-processing technology has gradually become a hot topic problem, especially in micro-scale milling chatter prevention with the development of the information age. In allusion to the actual case of micro-milling, the dynamic theoretical research is analyzed in-depth about the Fourier method and the average tooth angle method. Compared to two ways, the former is close to the actual processing requirements. The lobes are obtained use the two ways. Micro milling parameters are selected in the stable area and unstable region. Stable and non-stable curve and surface quality of machined parts are obtained after micro-milling test. The chatter points, non-chatter point and uncertain point are obtained in the high spindle speed, which are consistent with theoretical analysis. In contrast, the distribution of chatter points in the low-speed spindle speed. The reason is that the damping effect is produced in the micro-scale milling process. The research of micro-scale milling chatter, which has a certain significance to improve parts of precision machined parts, reduce the wear and tear of the micro-milling blade and extend micro-tool life.

scholarly journals Stability Analysis of Milling Process with Variable Spindle Speed and Pitch Angle considering Helix Angle and Process Phase Difference

2021 ◽  
Vol 2021 ◽  
pp. 1-15
Author(s):  
Gang Jin ◽  
Haotian Jiang ◽  
Jianxin Han ◽  
Zhanjie Li ◽  
Hua Li ◽  
...  
Keyword(s):  
Phase Difference ◽  
Pitch Angle ◽  
High Speed ◽  
Helix Angle ◽  
Stability Domain ◽  
Milling Process ◽  
Spindle Speed ◽  
The Stability ◽  
The Time Domain ◽  
Milling Chatter

Suppression of milling chatter by disrupting regenerative effect is a well-known method to obtain higher cutting stability domain. In this paper, a dynamic model of the milling process with variable spindle speed and pitch angle considering helix angle and process phase difference is presented. Then, an updated semidiscretization method is applied to obtain the stability chart. After the effectiveness of the proposed method is confirmed by comparisons with the previously published works and the time-domain simulations, lots of analyses are conducted to deeply evaluate the influence of the helix angle, the process phase difference, and feed per tooth on milling stability. Results show that the change of helix angle can result in significant stability discrepancies for both high-speed and low-speed regions. Though the process phase difference has the randomness and immeasurability in the practical application, it has an important influence on the stability and will result in a periodic evolution of the stability with a period π. Also, its recommended values are given for the practical milling process.

Simulation on the Wear of Micro Mill Cutter in Micro Milling

2010 ◽  
Vol 42 ◽  
pp. 476-479 ◽  
Author(s):  
Hai Jun Hu ◽  
Ya Zhou Sun ◽  
Ze Sheng Lu
Keyword(s):  
Milling Process ◽  
Spindle Speed ◽  
Micro Milling ◽  
Wear Depth ◽  
Forming Process ◽  
Milling Cutter ◽  
Cutting Heat ◽  
Milling Temperature ◽  
Contact Situation ◽  
Mill Cutter

In this paper, the prediction model of micro-milling cutters in milling process is established to simulate the wear depth in the software DEFORM-3D, the chips growing up an forming process. The paper studies the wear level during the cutting process of micro milling amount of feed per tooth and spindle speed. In this paper the cutting force, cutting heat flow and the contact situation between cutting tool and workpiece are considered in the simulation model. The paper uses abrasion mathematical model related to contact stress and temperature, etc. and studies the influence of the wear depth of milling cutter through the analysis of milling temperature and metal sliding characteristics. Finally, the FEA micro –soft ware is used to verify the change of amount of feed per tooth and the spindle speed with wear depth. The paper provides reasonable parameters for using the micro milling cutter better.

Investigation on Cutting Forces and Surface Finish in Mechanical Micro Milling of Zr-Based Bulk Metallic Glass

2019 ◽  
Vol 18 (01) ◽  
pp. 113-132
Author(s):  
Debajyoti Ray ◽  
Asit Baran Puri ◽  
Nagahanumaiah
Keyword(s):  
Surface Roughness ◽  
Metallic Glass ◽  
Cutting Force ◽  
Bulk Metallic Glass ◽  
Cutting Parameters ◽  
Milling Process ◽  
Spindle Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Axial Depth

Precision micro-component fabrication demands suitable manufacturing processes that ensure making of parts with good form and finish. Mechanical micro milling represents a flexible and powerful process that exhibits enhanced capability to create micro features. Bulk metallic glass (BMG) represents a young class of amorphous alloy material with superior mechanical and physical properties and finds appreciable micro scale applications like biomedical devices and implants, micro parts for sport items and various other micro- components. In the present work, an attempt has been made to analyze the influence of the cutting parameters like spindle speed, feed per tooth and axial depth of cut on the machinability of BMG, in mechanical micro-milling process. The micro-milling process performances have been evaluated concerning to cutting forces and surface roughness generated, by making full slots on the workpiece with solid carbide end mill cutters. The paper presents micro-machining results for bulk metallic glass machined with commercial micro-milling tool at low cutting velocity regime. Response surface methodology (RSM) has been employed for process modeling and subsequent analysis to study the influence of the combination of cutting parameters on responses within the selected domain of cutting parameters. It has been found that the effect of axial depth of cut on the cutting force components is remarkably significant. Cutting force components increases with the increase in axial depth of cut and decreases with increase in spindle speed. At low feed rate, cutting force in the feed direction (Fx, i.e., cutting force along x-direction) increases with a decrease in feed rate. This increase of force could be due to the possible ploughing effect. A similar pattern of variation has been observed with cutting force component in cross-feed direction (Fy) also. It has been found that effect of feed per tooth on the roughness parameter Ra is remarkably significant. Surface roughness increases with feed per tooth. Axial depth of cut does not contribute much to the surface roughness. Surface roughness decrease with the increase of spindle speed.

Study of Sound Signal for Tool Wear Monitoring System in Micro-Milling Processes

2009 ◽  
Author(s):  
Tin-Hong Chen ◽  
Ming-Chyuan Lu ◽  
Shean-Juinn Chiou ◽  
Ching-Yuan Lin ◽  
Ming-Hsing Lee
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Milling Process ◽  
Sound Signal ◽  
Micro Milling ◽  
Classifier Systems ◽  
Tool Monitoring ◽  
Micro Tool ◽  
End Mills ◽  
Cutting Processes

The modeling of tool wear effect on micro tool vibration and associated sound generation in the milling process was proposed and analyzed first for sound based micro tool monitoring. The LVQ based algorithms, as well as Fisher Linear Function, were also implemented for verify the sound signal capability for monitoring the tool wear condition in micro milling. Micro end-mills of 700 μm in diameter, a high speed spindle up to 60000 rpm, and sensors were installed to investigate the micro tool wear effect on the cutting system and provide the signals for modeling and system capability verification. Multi-sensor signals including the audible sound, cutting force and vibration were collected simultaneously during cutting processes. The simulation results were compared to experimental results and show good correlation to the collected sound signal. With the training and test sound signals collected in experiment, the classifier systems were established and the capability of sound based system were confirmed for detecting micro tool wear successfully.

The flank wear prediction in micro-milling Inconel 718

2018 ◽  
Vol 70 (8) ◽  
pp. 1374-1380 ◽  
Author(s):  
Xiaohong Lu ◽  
FuRui Wang ◽  
Zhenyuan Jia ◽  
Steven Y. Liang
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Milling Process ◽  
Micro Milling ◽  
Wear Prediction ◽  
Content Type ◽  
Micro Tool

Purpose Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software. Design/methodology/approach Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718. Findings A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously. Originality/value The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

Investigation on Adaptive Filter for On-Line Detection and Active Control of Chatter Vibration in Milling Process

2019 ◽  
Author(s):  
Shaoke Wan ◽  
Xiaohu Li ◽  
Wenjun Su ◽  
Jun Hong
Keyword(s):  
Active Control ◽  
Adaptive Filter ◽  
Rotation Frequency ◽  
Milling Process ◽  
Spindle Speed ◽  
Line Detection ◽  
Spindle Rotation ◽  
On Line ◽  
Milling Chatter ◽  
Periodic Components

Abstract On-line detection and active control of chatter vibration have always been important issues in milling process respectively. To some extent, the signals obtained with sensors determine the performance of on-line detection and active control of chatter. However, due to the characteristics of milling process, the obtained signals are mainly consisted with spindle rotation frequency and its harmonics, and the chatter components are usually submerged by these stable harmonics, imposing negative effects for the detection and active control of milling chatter. Then, it is highly needed to design a real-time filter to filter out the spindle rotation frequency and its harmonics. In this paper, an adaptive filter is designed to filter out the spindle speed related components. Moving average (MR) model and adaptive filter theory is utilized to estimate these periodic components. The influence of filter order and step size factor on the filter characteristics are also analyzed. Considering that the filter order needs to be adjusted under different cutting conditions, which will alter the filter’s performance, an improved adaptive filter is proposed. Experiments are also performed and the experimental results show that, not only the spindle speed related components can be filtered out effectively, but the chatter frequency components are amplified with appropriate initial step factor, which is beneficial for the detection of milling chatter at early stage. Meanwhile, the periodic components caused by the installation error and the other spindle speed related components can be effectively filtered out real-timely, preventing the saturation of actuator caused by these stable components.

Chatter prevention and improved finish of workpiece for a milling process

2009 ◽  
Vol 224 (4) ◽  
pp. 579-588 ◽  
Author(s):  
N-C Tsai ◽  
D-C Chen ◽  
R-M Lee
Keyword(s):  
Real Time ◽  
Acoustic Signal ◽  
Milling Process ◽  
Spindle Motor ◽  
Spindle Speed ◽  
Feedback Signal ◽  
Motor Speed ◽  
Acoustic Feedback ◽  
The Stability ◽  
Milling Chatter

This paper presents how real-time chatter prevention can be realized by feedback of an acoustic cutting signal. The efficacy of the proposed adaptive spindle speed tuning algorithm is verified by intensive experimental simulations. A pair of microphones, perpendicular to each other, is used to acquire the acoustic cutting signal resulting from milling chatter. A real-time feedback control loop is constructed for spindle speed compensation in such a way to ensure that the milling process is within the stability zone of the stability lobe diagram. The acoustic chatter signal index (ACSI) and the spindle speed compensation strategy (SSCS) are proposed to quantify the acoustic signal and actively to tune the spindle speed respectively. By converting the acoustic feedback signal into the ACSI, an appropriate spindle speed compensation rate (SSCR) can be determined by the SSCS based on a real-time chatter level or the ACSI. Accordingly, the compensation command, referred to as added-on voltage (AOV), is applied to increase/decrease the spindle motor speed. By employing the commercial software MATLAB/Simulink and the dSpace DS1104 interface module to implement the controller, the proposed chatter prevention algorithm is practically verified by intensive experiments. By inspection on the precision and quality of the workpiece surface after milling, the efficacy of the real-time chatter prevention strategy via acoustic signal feedback is further assured.

Machinability Study of SiC Nano-Particles Reinforced Magnesium Nanocomposites During Micro-Milling Processes

2010 ◽  
Author(s):  
Juan Li ◽  
Jian Liu ◽  
Chengying Xu
Keyword(s):  
Volume Fraction ◽  
High Volume ◽  
Cutting Parameters ◽  
Milling Process ◽  
Spindle Speed ◽  
Nano Particles ◽  
Micro Milling ◽  
Matrix Composites ◽  
Machined Surface ◽  
Machining Productivity

This paper experimentally investigates the machinability of Magnesium Metal Matrix Composites (Mg-MMCs) with high volume fractions of SiC nano-particles. Samples of Mg-MMCs with 5 Vol.%, 10 Vol.% and 15 Vol.% reinforcements of SiC nano-particles were studied and compared with pure Magnesium. Different feedrates and spindle speeds were chosen as varied cutting parameters. Cutting forces, surface morphology and roughness were measured to understand the machinability of the four different materials during the micro-milling process. Based on the experimental results, it is observed that the cutting force increases with the increase of the spindle speed, the feedrate and/or the volume fraction. A drastic increasing rate is observed when the nano-particles’ volume fraction is increased from 5 to 10 Vol.%. The effect of the volume fraction is also studied in frequency domain, combined with the effect of the spindle speed and feedrate. More detailed theoretical analysis will be further studied to better understand the effect of the volume fraction on the machined surface quality and machining productivity.

Effects of Tool Nose Corner Radius and Main Cutting-Edge Radius on Cutting Temperature in Micro-Milling Inconel 718 Process

2017 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Likun Si ◽  
Steven Y. Liang
Keyword(s):  
Three Dimensional ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Milling Cutter ◽  
Micro Scale ◽  
Cutting Edge Radius ◽  
Corner Radius ◽  
Edge Radius

Cutting temperature plays an important role in micro-scale cutting process because the dimension of the micro-milling cutter is relatively small and the wear of micro-milling cutter is sensitive to temperature. Considering the sidewall of a groove is formed by main cutting edge of the tool, and the bottom of a groove is formed by tool tip and the edge on the end of the tool. Therefore, effects of tool nose corner radius and main cutting edge radius on cutting temperature in micro-milling process cannot be ignored. However, few studies have been conducted on this issue. The effects of tool nose corner radius and main cutting edge radius on cutting temperature is investigated. A three-dimensional micro-milling Inconel718 model is established by using the software DEFORM3D. And the influence of tool nose corner radius and main cutting edge radius on the size and distribution of cutting temperature are studied by numerical simulation, which is verified by experiments. The work provide reference for the control of the size and distribution of the cutting temperature during micro-milling process.

Study on Machining Mechanism of Glass Using Discrete Element Method

2014 ◽  
Vol 577 ◽  
pp. 108-111 ◽  
Author(s):  
Ying Qiu ◽  
Mei Lin Gu ◽  
Feng Guang Zhang ◽  
Zhi Wei
Keyword(s):  
Discrete Element Method ◽  
Element Model ◽  
Discrete Element ◽  
Rake Angle ◽  
Milling Process ◽  
Micro Milling ◽  
Discrete Element Model ◽  
Machined Surface ◽  
Damage Depth ◽  
Element Method

The discrete element method (DEM) is applied to glass micromachining in this study. By three standard tests the discrete element model is established to match the main mechanical properties of glass. Then, indentating, cutting, micro milling process are simulated. Results show that the vertical damage depth is prevented from reaching the final machined surface in cutting process. Tool rake angle is the most remarkable factor influencing on the chip deformation and cutting force. The final machined surface is determined by the minimum cutting thickness per edge. Different cutting thickness, cutter shape and spindle speed largely effect on the mechanism of glass.

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