Modeling dynamic stability in high-speed micromilling of Ti–6Al–4V via velocity and chip load dependent cutting coefficients

Singh, None Dr. K. B.; Kartik, V.; Singh, Ramesh

doi:10.1016/j.ijmachtools.2015.06.002

Cited by 56 publications

(16 citation statements)

References 19 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Due to the size reduction, the micro-milling process requires small-diameter tools (slender tools), and their stiffness is therefore often one order of magnitude lower than those used in conventional sizes. This limited stiffness is a major obstacle, when machining difficult-to-cut materials, such as hardened steels and titanium alloys [134]. In addition to the low stiffness of the tools, the high specific cutting force-at small depth of cut values-also makes the optimization of the micro-milling process more difficult [135].…”

Section: Vibrations In Micro-millingmentioning

confidence: 99%

“…They confirmed that the stabilisation of the tool and cutting process could be achieved by increasing speeds. Singh et al [134] also stated that the chip load should be reduced in the case of high speeds, but this may result in an intensification of the ploughing phenomenon, which can result in even an order of magnitude higher vibrations.…”

Section: Vibrations In Micro-millingmentioning

confidence: 99%

“…As it is well-known, vibrations and chatter often cause poor surface quality and tool failure due to unstable cutting conditions [37,38,134,140]. Considering the special characteristics of the micro-milling process, such as the (i) small diameter of tool (< 1 mm), (ii) relatively large tool run-out and (iii) deformations; it can be concluded that the dynamic behaviour of the process is extremely complex [38].…”

Section: Vibrations In Micro-millingmentioning

confidence: 99%

See 2 more Smart Citations

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

134

View full text Add to dashboard Cite

Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

show abstract

Section: Vibrations In Micro-millingmentioning

confidence: 99%

Section: Vibrations In Micro-millingmentioning

confidence: 99%

Section: Vibrations In Micro-millingmentioning

confidence: 99%

See 1 more Smart Citation

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

134

View full text Add to dashboard Cite

show abstract

“…Jing et al [9] developed finite element model for micro-milling process under different uncut chip thicknesses and speeds, and the force coefficients were determined through a nonlinear algorithm. Singh et al [10] incorporated the mechanistic force model based on chip load and velocity depended coefficient into the analytical stability model during micro-milling of Ti6Al4V.…”

Section: Introductionmentioning

confidence: 99%

Overhang length effect during micro-milling of Inconel 718 superalloy

Kuram

2019

J Braz. Soc. Mech. Sci. Eng.

View full text Add to dashboard Cite

The accuracy of machining force relies on the accuracy of the cutting force coefficients which are determined by calibration experiments and are related to cutting tool-workpiece material couple. To this end, a mechanistic model was established to anticipate machining forces that occurred during micro-milling under different tool overhang lengths. This study assumed that the cutting force coefficients varied with the tool overhang length, and this assumption was proved by some micro-milling experiments. Force coefficients were computed by linearly fitting the experimental force data. In the current work, also wear on tool and burr formation were observed as functions of feed per tooth and overhang length. The overhang length of 15 and 20 mm significantly reduced the diameter of the micro-tool as compared to the overhang length of 10 mm. The obtained results showed that cutting forces and top burr width increased with the increasing overhang length. It was also found that the values of cutting and edge coefficients differed with the overhang length.

show abstract

“…However, the continuous chip flow breaks down and serrated chips begin to form with the increasing cutting speed [5,6]. The chip morphology transition from continuous to serrated chips leads to the intense cutting force fluctuation [7][8][9][10], which is generally believed harmful for the cutting tool and surface integrity [11][12][13][14]. Therefore, the serrated chips should be suppressed in order to improve the surface integrity of machined components during HSM.…”

Section: Introductionmentioning

confidence: 99%

Enhancing surface integrity by high-speed extrusion machining

Liu

Cai

Shang

et al. 2016

Int J Adv Manuf Technol

View full text Add to dashboard Cite

High-speed machining (HSM) is an advanced machining technology to form components. However, the poor surface integrity tends to appear due to chip flow instability in HSM. It is found that the surface integrity results from the competition of shear deformation instability between in primary shear zone (PSZ) and in separating shear zone (SSZ). To improve the surface integrity of machined components, the systematic high-speed extrusion machining (HSEM) experiments of magnesium alloy AZ31B with different constraint extrusion factors (CEFs) were carried out. The instability of shear deformation in PSZ is suppressed, and the microwaves on machined surface disappear when CEF is equal to or larger than a certain value. The measurements of the machined surface show that an improvement of surface integrity is achieved if CEF exceeds a certain value. The theoretical model for HSEM was established to elucidate the critical CEF. The underlying physics of surface integrity in HSEM is further revealed. The experimental results verify the validity of the theoretical model.

show abstract

Modeling dynamic stability in high-speed micromilling of Ti–6Al–4V via velocity and chip load dependent cutting coefficients

Cited by 56 publications

References 19 publications

A review on micro-milling: recent advances and future trends

A review on micro-milling: recent advances and future trends

Overhang length effect during micro-milling of Inconel 718 superalloy

Enhancing surface integrity by high-speed extrusion machining

Contact Info

Product

Resources

About