Modeling of dynamic micro-milling cutting forces

Uncertainty analysis of force coefficients during micromilling of titanium alloy

“…As a result, the round cutting edge ploughs the uncut material onto the work surface. Malekian et al [5] proposed a mechanistic micromilling force model by considering shearing and ploughing phases separately. They were able to simulate dynamic machining forces for the micromilling of aluminum 6061.…”

“…In a recent study, Oliaei and Karpat [21] showed that built-up edge formation in front of the cutting edge reduces this ratio down to 10% during microturning of titanium alloy Ti6Al4V. Figure 9 shows the micromilling process model proposed by Malekian et al [5]. The forces acting on the cutting edge are defined with respect to the uncut chip thickness (h).…”

“…As for the region where h < h c , ploughing condition dominates the machining forces. Malekian et al [5] modeled these forces proportional to the volume of interference between the tool and the workpiece. The ploughing volume regarding a discretized disk element of a tooth is related to the area underneath the tool as V p = A p .dz.…”

“…Force modeling based on process input parameters is usually considered as the first step in process modeling. Mechanistic process modeling is usually preferred to model process forces in micromilling where the relationship between the work material and the cutting edge is obtained through cutting, edge, and ploughing force coefficients [5][6][7]. These coefficients are often calculated from either experimental measurements of process forces or finite element-based simulation models [8].…”

“…A mechanistic micromilling model from the literature [5] has been adopted, and the probability distributions of cutting, edge, and ploughing force coefficients were calculated. As a result of uncertainty analysis, the mean and standard deviations of the micromilling forces can be estimated.…”