Modeling of three-dimensional cutting forces in micro-end-milling

Li, Chengfeng; Lai, Xinmin; Li, Hongtao; Ni, Jun

doi:10.1088/0960-1317/17/4/001

Cited by 100 publications

(45 citation statements)

References 12 publications

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“…Zaman et al [12] developed a model which determined the theoretical chip area at any specific angular position of the cutting tool tip. Li et al [23] presented a new algorithm to calculate the actual chip thickness considering the trochoidal trajectory of tool tip with run-out and the minimum chip thickness (MCT) effects.…”

Section: Analytical Chip Thicknessmentioning

confidence: 99%

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

2018

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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.

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Section: Analytical Chip Thicknessmentioning

confidence: 99%

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

2018

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“…If the angle between feed direction and X _ TCF is not zero, B matrix transforms the cutting forces into the tool coordinate frame: A comprehensive chip thickness model is developed in literatures (Li et al 2007). The same chip thickness model is utilized in the developed force prediction model.…”

Section: Cam Model Of the Workpiece Used In Micro Millingmentioning

confidence: 99%

Parameter Adaptive

2014

CIRP Encyclopedia of Production Engineering

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“…An analytical expression for the chip thickness of micro end milling considering the tool runout was first studied by Bao and Tansel [11]. Li et al [12] proposed an instantaneous uncut chip thickness algorithm for micro milling operation by considering the combination of an exact trochoidal trajectory of the tool tip and the tool runout.…”

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

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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.

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Modeling of three-dimensional cutting forces in micro-end-milling

Cited by 100 publications

References 12 publications

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

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

Parameter Adaptive

An improved cutting force model for micro milling considering machining dynamics

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