Modeling micro-end-milling operations. Part II: tool run-out

Bao, W.Y.; Tansel, İbrahim N.

doi:10.1016/s0890-6955(00)00055-9

Cited by 155 publications

(60 citation statements)

References 7 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…To calculate the chip thickness of the machined material, Bao and Tansel [42,43] proposed a cutting force model that considered the effect of tool tip trajectory. However, this model did not consider the effect of the negative rake angle of the cutting tool and elastic-plastic deformation of the workpiece material in micro-cutting; both of these factors significantly differ from that in macro-cutting.…”

Section: Micro-cuttingmentioning

confidence: 99%

Recent advances in micro- and nano-machining technologies

Gao

Huang

2017

Front. Mech. Eng.

View full text Add to dashboard Cite

Device miniaturization is an emerging advanced technology in the 21st century. The miniaturization of devices in different fields requires production of micro-and nano-scale components. The features of these components range from the sub-micron to a few hundred microns with high tolerance to many engineering materials. These fields mainly include optics, electronics, medicine, bio-technology, communications, and avionics. This paper reviewed the recent advances in micro-and nano-machining technologies, including micro-cutting, micro-electrical-discharge machining, laser micro-machining, and focused ion beam machining. The four machining technologies were also compared in terms of machining efficiency, workpiece materials being machined, minimum feature size, maximum aspect ratio, and surface finish.

show abstract

Section: Micro-cuttingmentioning

confidence: 99%

Recent advances in micro- and nano-machining technologies

Gao

Huang

2017

Front. Mech. Eng.

View full text Add to dashboard Cite

show abstract

“…Spindle Runout: The problem of small chip thickness is complicated by the fact that typical milling spindles have radial runout at the tool tip on the order of 1 to 2 micrometers or more [3] [4]. This means that in ordinary operation, some teeth on the cutter may not contact the workpiece at all during rotation, while others are forced to cut chips up to several times the desired thickness.…”

Section: Cutting Edge Radiusmentioning

confidence: 99%

“…The cutting tools are also scaled by the same factor. If the spindle speed is constant for both operations, the feed rate must scale by a factor of k 2 to maintain a constant bending stress in the tool, while the axial and radial depths of cut each scale by the factor, k. Therefore, the MRR scales by k 4 , while the volume of material to be removed scales by k 3 . This means that if a certain mechanical component is to be created by an end milling operation and a geometrically similar component one-tenth the size is also to be created, the operation will take approximately ten times as long to complete.…”

Section: Summary Of Findingsmentioning

confidence: 99%

Next generation spindles for micromilling.

Pathak

Payne

Gill

et al. 2004

View full text Add to dashboard Cite

There exists a wide variety of important applications for micro-and meso-scale mechanical systems in the commercial and defense sectors, which require high-strength materials and complex geometries that cannot be produced using current MEMS fabrication technologies. Micromilling has great potential to fill this void in MEMS technology by adding the capability of free form machining of complex 3D shapes from a wide variety and combination of traditional, well-understood engineering alloys, glasses and ceramics. Inefficiencies in micromilling result from the relationships between a cutting tool's breaking strength, the applied cutting force, and the metal removal rate. Because machining times in mesofeatures scale inversely to the part size, a feature 1/10 th as large will take 10 times as long to machine. Also, required chip sizes of 1 m or less are cut with tools having edge radius of 2-3 m, the cutting edge effectively has a highly negative rake angle, cutting forces are increased significantly causing chip loads to be further reduced and the machining takes even longer than predicted above. However, cutting forces do not increase with cutting speed, so faster spindles with reduced tool runout are the path to achieve efficient mesoscale milling.This research explored the development of new ultra-high speed micromilling spindles. A novel air-bearing spindle design is discussed that will run at very high speeds (450,000 rpm) and provide very minimal runout allowing the best use of micromilling cutters and reducing overall 3 machining time drastically. Two generations of this spindle design were completed; one with an air bearing supported tool shaft and one with a novel rolling element bearing supported tool shaft. Both designs utilized friction-drive systems that relied on diameter differences between the drive wheel (operating at speeds up to 90,000 rpm) and the tool shaft to achieve high rotational tool speeds. Runout, stiffness, and machining tests were conducted with the spindle designs and though they both showed promise for ultra-high speed machining, runout issues in the friction drive and in the stock tools kept the system from achieving sustained machining capability.4

show abstract

“…A well-developed cutting force model with precise force prediction can assist operators in choosing the optimal cutting parameters; furthermore, the predicted toolworkpiece dynamic displacement can be used for tool path adjustment in order to increase the accuracy of machined parts and reduce tool breakage [7][8][9]. Therefore, developing an accurate cutting force model becomes imperative for micro milling process.…”

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

View full text Add to dashboard Cite

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.

show abstract

Modeling micro-end-milling operations. Part II: tool run-out

Cited by 155 publications

References 7 publications

Recent advances in micro- and nano-machining technologies

Recent advances in micro- and nano-machining technologies

Next generation spindles for micromilling.

An improved cutting force model for micro milling considering machining dynamics

Contact Info

Product

Resources

About