Force modelling in micromilling of channels

Attanasio, Aldo; Garbellini, Alessandro; Ceretti, Elisabetta; Giardini, Claudio

doi:10.1504/ijnm.2015.075238

Cited by 12 publications

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“…In particular, dial indicators [ 23 , 27 , 28 ], microscopes [ 29 ], capacitive sensors [ 30 ], and laser sensors [ 31 ] have been utilized for this purpose. Other strategies defined the values of the run-out parameters by optimization algorithms [ 25 , 32 , 33 ]. As a general remark, when applying these methods, the cutting force signals coming from experimental data are utilized for setting the best run-out values that minimize an objective function.…”

Section: Tool Run-out In Micro Millingmentioning

confidence: 99%

“…In a previous work [ 25 ], the author presented a geometrical model of the cutting edge trajectories of a two-flute micro end mill that considered tool run-out.…”

Section: Geometrical Model Of Run-outmentioning

confidence: 99%

“…As demonstrated in [ 25 ], the trajectories of the first cutting edge (A in Figure 2 ) and the second cutting edge (B in Figure 2 ) can be expressed by Equations (6)–(9).

where f is the tool feed defined by Equation (10).…”

Section: Geometrical Model Of Run-outmentioning

confidence: 99%

“…Consequently, this procedure requires high computational time. Attanasio et al [ 25 ] proposed a procedure based on the particles swarm optimization strategy for calibrating the coefficients of an analytical model of cutting force in micro milling, including tool run-out.…”

Section: Introductionmentioning

confidence: 99%

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Tool Run-Out Measurement in Micro Milling

Attanasio

2017

Micromachines

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The interest in micro manufacturing processes is increasing because of the need for components characterized by small dimensions and micro features. As a result, researchers are studying the limitations and advantages of these processes. This paper deals with tool run-out measurement in micro milling. Among the effects of the scale reduction from macro to micro, tool run-out plays an important role, affecting cutting force, tool life, and the surface integrity of the produced part. The aim of this research is to develop an easy and reliable method to measure tool run-out in micro milling. This measuring strategy, from an Industry 4.0 perspective, can be integrated into an adaptive model for controlling cutting force, with the aim of improving the production quality and the process stability, while at the same time reducing tool wear and machining costs. The proposed procedure deduces tool run-out from the actual tool diameter, the channel width, and the cutting edge’s phase, which is estimated by analyzing the cutting force signal. In order to automate the cutting edge phase measurement, the suitability of two functions approximating the force signal was evaluated. The developed procedure was tested on data from experimental tests. A Ti6Al4V sample was machined using two coated micro end mill flutes made by SECO setting different run-out values. The results showed that the developed procedure can be used for tool run-out estimation.

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Section: Tool Run-out In Micro Millingmentioning

confidence: 99%

“…In a previous work [ 25 ], the author presented a geometrical model of the cutting edge trajectories of a two-flute micro end mill that considered tool run-out.…”

Section: Geometrical Model Of Run-outmentioning

confidence: 99%

“…As demonstrated in [ 25 ], the trajectories of the first cutting edge (A in Figure 2 ) and the second cutting edge (B in Figure 2 ) can be expressed by Equations (6)–(9).

where f is the tool feed defined by Equation (10).…”

Section: Geometrical Model Of Run-outmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Tool Run-Out Measurement in Micro Milling

Attanasio

2017

Micromachines

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“…Li et al proposed a new nominal uncut chip thickness algorithm for micro-scale end-milling by considering the combination of an exact trochoidal trajectory of the tool tip and tool run-out [ 6 ]. Attanasio et al investigated the modeling procedure for forecasting cutting forces in micro-channel machining, considering all phenomena involved at the micro-scale [ 7 ]. Arizmendi et al presented a model for predicting surface topography in peripheral milling operations taking tool vibration during the cutting process into account [ 8 ].…”

Section: Introductionmentioning

confidence: 99%

Modeling the Influence of Tool Deflection on Cutting Force and Surface Generation in Micro-Milling

et al. 2017

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In micro-milling, cutting forces generate non-negligible tool deflection, which has a significant influence on the machining process and on workpiece accuracy. This paper investigates the tool deflection during micro-milling and its effect on cutting force and surface generation. The distribution of cutting forces acting on the tool is calculated with a mathematical model that considers tool elasticity and runout, and the tool deflection caused by the cutting forces is then obtained. Furthermore, an improved cutting force model and side wall surface generation model are established, including the tool deflection effect. Both cutting force and surface simulation models were verified by the micro-end-milling experiment, and the results show a very good agreement between the simulation and experiments.

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Comparison Between Micro Machining of Additively Manufactured and Conventionally Formed Samples of Ti6Al4V Alloy

Abeni

Ginestra

Attanasio

2021

Lecture Notes in Mechanical Engineering

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The paper deals with micro mechanical machining process of Ti6Al4V alloy. A comparison between additively manufactured samples and conventionally fabricated samples with mill annealed structure was performed. Powder Bed Fusion Laser Based (PBF-LB) and Beam Based (PBF-BB) processes were used to produce samples with a building direction of 0° and 30° in relation to the plate. The Minimum Uncut Chip Thickness (MUCT) was determined to investigate the removal behavior during slot machining with rounded-edges micro-tools. The cutting forces were measured, and the loads were utilized to calculate Specific Cutting Force (SCF). It was reported as a function of the feed per tooth (fz) to investigate when the transition between shearing and ploughing occurs. Once the MUCT was identified, further micro machining tests were performed by changing the feed rate and speed rate. The surface roughness and cutting force of the machined samples were measured to deeply investigate the effects of ploughing regime. The dependence of roughness on the sample fabrication technique and on the process parameters of micro milling was highlighted.

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Force modelling in micromilling of channels

Cited by 12 publications

References 0 publications

Tool Run-Out Measurement in Micro Milling

Tool Run-Out Measurement in Micro Milling

Modeling the Influence of Tool Deflection on Cutting Force and Surface Generation in Micro-Milling

Comparison Between Micro Machining of Additively Manufactured and Conventionally Formed Samples of Ti6Al4V Alloy

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