Comparative study of stability predictions in micro-milling by using cutting force models and direct cutting force measurements

The vibration in milling process plays a key role in machining, which will significantly affect the machining quality of workpiece. Some vibrations have negative influences on the workpiece surface, while particular vibrations are able to improve machining stability. Therefore, it is critical to distinguish the influence of different types of vibration on the machining quality. A simulation method of undeformed chip thickness considering process vibration is presented in this article, in which a finite element model is established to analyze the dynamic milling process of 7075-T651 aluminum alloy from the aspects of cutting force and temperature. A series of experiments are carried out to verify the effectiveness of the simulation model, and the results show that the proposed model is accurate in predicting milling force and temperature. Furthermore, the effect of milling vibration on machining performance is studied with the proposed method, in which the relationship between amplitude-frequency characteristics of vibration and milling forcetemperature fluctuation is revealed. The results show that the proposed method can define the influence of milling vibration and provide a basis for distinguishing favorable and unfavorable vibration parameters of machining quality in milling.

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An unformed chip thickness approach to study the influence of process vibration on machining performance in milling

Guo

Wang

Guo

et al. 2022

Int J Adv Manuf Technol

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Conventional and micro scale finite element modeling for metal cutting process: A review

Wang

Yue

Liu

et al. 2024

Chinese Journal of Aeronautics

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Machining dynamics and chatters in micro-milling: A critical review on the state-of-the-art and future perspectives

BAI,

WANG,

CHENG

et al. 2024

Chinese Journal of Aeronautics

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Comparative study of stability predictions in micro-milling by using cutting force models and direct cutting force measurements

Cited by 5 publications

References 7 publications

An unformed chip thickness approach to study the influence of process vibration on machining performance in milling

An unformed chip thickness approach to study the influence of process vibration on machining performance in milling

Conventional and micro scale finite element modeling for metal cutting process: A review

Machining dynamics and chatters in micro-milling: A critical review on the state-of-the-art and future perspectives

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