Mechanistic modeling and accurate measurement of micro end milling forces

Park, Simon S.; Malekian, Mohammad

doi:10.1016/j.cirp.2009.03.060

Cited by 97 publications

(37 citation statements)

References 8 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Therefore, substitute the solutions of H min , H max , α A , and α B into Eqs. (2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13) to to get the cutting force values.…”

Section: Mechanical Model Of Micro-milling Force Considering Tool Runoutmentioning

confidence: 99%

“…The conclusion was the amplitude of the tool tip increased with the increasement of the spindle rotation speed, tool runout, and tilt angle. Park et al [9] established an accurate micro-milling force prediction model based on the shear mechanism dominated by the shear force and plough force. Rodríguez et al [10] built a micro-milling force model which considered the tool runout, tool deflection, and size effect.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Modeling and experimental study on the force of micro-milling titanium alloy based on tool runout

Feng

et al. 2016

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Geometry defect of tools and assembling error (such as tool runout) is inevitable in the machining process and cannot be ignored in micro-milling processing mechanism. Besides, it also impacts the micro-milling force. Therefore, it plays an important role on impacting surface quality in micro-milling. In the present paper, the milling force model is established for the micro-milling process with considering tool runout, undeformed chip thickness, tool slope angle, shear angle, friction angle, and equivalent rake angle. The model for three-directional micromilling force is proposed. Furthermore, the cutting forces with different tool runouts are analyzed. The formation of the step that is on the surface and found in the experiments is made clear. Titanium alloy is applied in a series of micro-milling experiments to verify the model of micro-milling force with analyzing the step widths of machined groove edges. The micro-milling process is further comprehended though the model. It helps to judge the surface quality that is affected by tool runout though the analysis of variation of milling force.

show abstract

“…Therefore, substitute the solutions of H min , H max , α A , and α B into Eqs. (2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13) to to get the cutting force values.…”

Section: Mechanical Model Of Micro-milling Force Considering Tool Runoutmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modeling and experimental study on the force of micro-milling titanium alloy based on tool runout

Feng

et al. 2016

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…The smallest scientifically investigated [3] and commercially available [4] diameter of a micromilling tool is d = 0.01 mm. In comparison to electric discharge micromachining (µEDM) and laser micro ablation, micromachining processes are characterized by a higher rate of material removal and a better surface quality [5].…”

Section: Introductionmentioning

confidence: 99%

Prediction of Feed-Rate Slowdowns in Precise Micromilling Processes

Meijer

Krebs

Wiederkehr

et al. 2018

JMMP

View full text Add to dashboard Cite

Abstract:In a production of filigree and complex geometries, different NC-controlled processes such as laser cutting, EDM milling, and micromachining require a constant feed rate to ensure high-quality manufacturing results. Due to the technically limited acceleration ability of the machine tool axes, the nominal feed cannot always be achieved. This in particular is the case when the machine tool has to perform a significant change of direction in corners. In this paper, the impact of too low feed rates on the process of precise micromilling of a hardened high-speed steel AISI (M3:2) 63 ± 1 HRC) is discussed. An unattained feed rate leads to a ploughing dominated process with a high burr formation resulting in a huge potential loss of micromilling processes. Furthermore, a simulation approach is presented which allows the prediction of the actually achieved feed rate. The developed machine model provides a reliable method to identify critical areas in the entire NC program.

show abstract

“…A number of cutting force models are proposed and studies for microcutting processes [1][2][3][4][5][6][7][8], which falls in four categories, i.e. analytical modelling [9][10][11][12], numerical modelling [7,8,13], empirical modelling [14][15][16][17] and hybrid modelling (combining the strengths of previous three modelling approaches). Davoudinejad et al [18] proposed a 3D FEM for studying the cutting forces in full slot end milling process.…”

Section: Introductionmentioning

confidence: 99%

Investigation on Innovative Dynamic Cutting Force Modelling in Micro-milling and Its Experimental Validation

2018

View full text Add to dashboard Cite

In this paper, an innovative cutting force modelling concept is presented by modelling cutting forces against micro-cutting processes such as micro-milling, ultraprecision turning and abrasive micromachining, and also taking account of microcutting dynamics. The modelling represents the underlying micro-cutting mechanics and physics in micro-milling in an innovative multi-scale manner, i.e. the specific cutting force at the unit length, unit area and unit volume by considering the size effect, cutting fracture energy, the material modulus, and the cutting heat and temperature partition. A novel instantaneous chip thickness algorithm is introduced to analyse the real chip thickness by taking account of the effects of the micro-tool geometry change brought up by the tool run-out and further contribute to the force model through a numerical iterative algorithm. The measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. This is further utilized to calibrate the model coefficients using least square method. The cutting force modelling is evaluated and validated through well-designed micro-milling trials, which can be used for optimizing the cutting process and tool cutting performance in particular.

show abstract

Mechanistic modeling and accurate measurement of micro end milling forces

Cited by 97 publications

References 8 publications

Modeling and experimental study on the force of micro-milling titanium alloy based on tool runout

Modeling and experimental study on the force of micro-milling titanium alloy based on tool runout

Prediction of Feed-Rate Slowdowns in Precise Micromilling Processes

Investigation on Innovative Dynamic Cutting Force Modelling in Micro-milling and Its Experimental Validation

Contact Info

Product

Resources

About