Cutting force model considering tool edge geometry for micro end milling process

Kang, In-Soon; Kim, Jeong Suk; Seo, Y.W.

doi:10.1007/s12206-007-1110-x

Cited by 29 publications

(11 citation statements)

References 12 publications

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“…10 deformation and sliding mechanisms contributes to the cutting energy, especially when the tool edge radius comes to be on the order of the undeformed chip thickness [40].…”

Section: Accepted Manuscriptmentioning

confidence: 99%

Experimental study of coated tools effects in dry cutting of natural fiber reinforced plastics

Chegdani

Mezghani

Mansori

2015

Surface and Coatings Technology

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This work aims to investigate the tribological effects of coated tools on the surface finish of natural fiber reinforced plastics (NFRP) during profile milling process with particular emphasis on the natural fiber cutting mechanisms and tool wear. Both up-milling and downmilling configurations were considered. The cutting experiments were carried out on unidirectional flax fibers reinforced polypropylene resin (UDF/PP) using three different cutting tools. Uncoated tungsten carbide, titanium diboride (T i B 2 ) coated and diamond coated were used to conduct profile milling tests. Tribological cutting contacts were evaluated by measuring the specific cutting energy. Surface state was acquired by scanning electronic microscope (SEM) and optical microscope (OM). Surface topography was measured using 2D Surfascan stylus profilometer. Machined NFRP surface finish was characterized using standard and multiscale analysis based on wavelets transform.Results show that the cutting edge radius made by tool coating has a significant effect on surface finish. Natural fiber shearing is more efficient once the removed chip thickness exceeds the cutting edge radius value. Moreover, it had been demonstrated that the pertinent scales for surface finish analysis are between 50 µm and 1 mm which correspond to the multiscale fiber reinforcement structure. Furthermore, and unlike the uncoated tool, T i B 2 and diamond coatings allow a good wear resistance of the cutting tools against the tribological solicitations of flax composites machining.

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“…10 deformation and sliding mechanisms contributes to the cutting energy, especially when the tool edge radius comes to be on the order of the undeformed chip thickness [40].…”

Section: Accepted Manuscriptmentioning

confidence: 99%

Experimental study of coated tools effects in dry cutting of natural fiber reinforced plastics

Chegdani

Mezghani

Mansori

2015

Surface and Coatings Technology

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“…They demonstrated that the ploughing ratio depends on the predicted cutting force ratio Fc/Ft. Thiele and Melkote [8] and Kang et al [9] confirmed that the cutting edge geometry has a significant effect on the cutting force components. Karpat and Özel investigated the friction characteristics of tools with curvilinear edges [10].…”

Section: Introductionmentioning

confidence: 94%

Distribution of unit forces on the tool edge rounding in the case of finishing turning

Storch

Zawada-Tomkiewicz

2011

Int J Adv Manuf Technol

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An experimental investigation was conducted to determine the effects of tool cutting edge geometry on the cutting forces in finish turning, where the applied feed and depth of cut are small and often comparable with the tool edge radius. If a tool with large tool edge radius is used in finish turning, the ploughing effect begins to determine the machined surface. This paper presents the results of analytical considerations concerning the unit forces on a cutting edge. The aim of this paper is to indicate possibilities of modelling the unit forces and stress distribution based on cutting resistance. The forces calculated in the feed and cutting speed directions were projected onto the tangential and normal directions of the rounded cutting edge surface. An important assumption in all the considerations was that the thermo-mechanical properties of the materials used remained constant. The minimum thickness of cut was defined, and some characteristic points were identified dividing the cutting zone into three subregions: where a chip is formed, where the machined surface is formed and an unstable region.

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“…An analytical expression for the chip thickness of micro end milling considering the tool runout was first studied by Bao and Tansel [11]. Li et al [12] proposed an instantaneous uncut chip thickness algorithm for micro milling operation by considering the combination of an exact trochoidal trajectory of the tool tip and the tool runout. Different from conventional cutting, in micro milling, the cutting tool edge radius has an important influence on the cutting mechanism; therefore, Kang et al [13] established a cutting force model considering the edge radius of micro cutting tools, in which the ploughing effect at the tool edge and the sliding on the flank face were modelled.…”

Section: Introductionmentioning

confidence: 99%

An improved cutting force model for micro milling considering machining dynamics

Chen

Teng

Huo

et al. 2017

Int J Adv Manuf Technol

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Micro milling, as a versatile micro machining process, is kinematically similar to conventional milling; however, it is significantly different from conventional milling with respect to chip formation mechanisms and uncut chip thickness modelling, due to the comparable size of the edge radius to the chip thickness, and the small per-tooth feeding. Considering tool runout and dynamic displacement between the tool and the workpiece, the contour of the workpiece left by previous tool paths is typically in a wavy form, and the wavy surface provides a feedback mechanism to cutting force generation because the instantaneous uncut chip thickness changes with both the vibration during the current tool path and the surface left by the previous tool paths. In this study, a more accurate uncut chip thickness model was established including the precise trochoidal trajectory of the cutting edge, tool runout and dynamic modulation caused by the machine tool system vibration. The dynamic regenerative effect is taken into account by considering the influence of all the previous cutting trajectories using numerical iteration; thus, the multiple time delays (MTD) are considered in this model. It is found that transient separation of the tool-workpiece occurring at a low feed per tooth, caused by MTD and the existing cutting force models, is no longer applicable when transient tool-workpiece separation occurs. Based on the proposed uncut chip thickness model, an improved cutting force model of micro milling is developed by full consideration of the ploughing effect and elastic recovery of the workpiece material. The proposed cutting force model is verified by micro end milling experiments, and the results show that the proposed model is capable of producing more accurate cutting force prediction than other existing models, particularly at small feed per tooth.

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Cutting force model considering tool edge geometry for micro end milling process

Cited by 29 publications

References 12 publications

Experimental study of coated tools effects in dry cutting of natural fiber reinforced plastics

Experimental study of coated tools effects in dry cutting of natural fiber reinforced plastics

Distribution of unit forces on the tool edge rounding in the case of finishing turning

An improved cutting force model for micro milling considering machining dynamics

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