Modelling of the Influence of Tool Runout on Surface Generation in Micro Milling

Abstract

Micro milling is a flexible and economical method to fabricate micro components with three-dimensional geometry features over a wide range of engineering materials. But the surface roughness and micro topography always limit the performance of the machined micro components. This paper presents a surface generation simulation in micro end milling considering both axial and radial tool runout. Firstly, a surface generation model is established based on the geometry of micro milling cutter. Secondly, the influence of the runout in axial and radial directions on the surface generation are investigated and the surface roughness prediction is realized. It is found that the axial runout has a significant influence on the surface topography generation. Furthermore, the influence of axial runout on the surface micro topography was studied quantitatively, and a critical axial runout is given for variable feed per tooth to generate specific surface topography. Finally, the proposed model is validated by means of experiments and a good correlation is obtained. The proposed surface generation model offers a basis for designing and optimizing surface parameters of functional machined surfaces.

Precision micro-milling process: state of the art

“…The significance of tool runout is that it has a major influence on the cutting force. This is due to the displacement being in the same order of magnitude as the feed per tooth, which therefore has a large influence on the surface roughness generated, as determined recently by Chen et al [ 99 ]. They also found that axial runout in particular limited the achievable surface roughness.…”

“…Therefore, axial displacement of the tool causes its tip to rotate off center relative to the spindle axis. Cutting tools will generally be less tolerant to axial runout, especially for micro-milling operations in both side and face milling operations, but axial runout has a considerable influence on the surface topography generation in face milling [ 99 ]. The total tool runout is therefore the sum of both axial and radial runouts, with the effect becoming even more significant in the micro-milling domain, as demonstrated by Fig.…”

Influence of Groove Structure Parameters Based on Optimal Mass Transfer Coefficient on Vaporization Characteristics and Sealing Performance of Liquid Film Mechanical Seals

“…This model has the advantages of a simple form, relatively easy calculation, and high reliability. Chen et al [15][16][17] established a vaporization phase transition calculation model based on the viscosity-temperature effect. The saturation temperature with the pressure change equation, fluid internal friction effect, and the phase transition mechanism of the spiral groove liquid film seal were analyzed and discussed.…”