Radial depth of cut stability lobe diagrams with process damping effects

Tyler, Christopher; Troutman, John R.; Schmitz, Tony L.

doi:10.1016/j.precisioneng.2014.11.004

Cited by 22 publications

(4 citation statements)

References 20 publications

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“…Therefore, to prevent chatter and unstable machining conditions, accurate models of the dynamics of the micro-milling system are necessary to predict the relationships between the workpiece material, structural dynamics of the machine tool including toolholders, tool geometry, and cutting conditions. By analyzing these models, a stability lobe diagram (SLD) can be created, which will offer insights into ideal machining parameters that can be chosen to prevent process instabilities such as chatter, greatly improving the machining efficiency [ 109 ].…”

Section: Fundamentals Of the Processmentioning

confidence: 99%

“…However, only stability prediction results considering the shear effect were obtained for the SLDs drawn. Tyler et al [ 116 ] presented a method for producing SLDs that included process damping ranges (low cutting speed) and high cutting speeds. This method defined the stability boundaries by radial rather than axial depth of cut, because of the approach taken by computer-aided modeling toolpath programs.…”

Section: Fundamentals Of the Processmentioning

confidence: 99%

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Precision micro-milling process: state of the art

2020

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Micro-milling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy, and efficiency in a wide range of materials. In particular, the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain, as well as for rapid micro-texturing and micro-patterning, which will have great importance in the near future in bio-implant manufacturing. This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries. However, inherent physical process constraints of machining arise as macro-milling is scaled down to the microdomain. This leads to some physical phenomena during micro-milling such as chip formation, size effect, and process instabilities. These dynamic physical process phenomena are introduced and discussed in detail. It is important to remember that these phenomena have multifactor effects during micro-milling, which must be taken into consideration to maximize the performance of the process. The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved. Additionally, newly developed processes that combine conventional micro-milling with other technologies, which have great prospects in reducing the issues related to the physical process phenomena, are also introduced. Finally, the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.

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Section: Fundamentals Of the Processmentioning

confidence: 99%

Section: Fundamentals Of the Processmentioning

confidence: 99%

Precision micro-milling process: state of the art

2020

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“…Some challenges that commonly occur on micro milling are size effect or uncut chip thickness (UTC) [12], built-up edge (BUE) [13], burr formation [14], incorrect tool radius [15], tool deflection and tool run-out [16], and chatter and vibration [17]. Wang et al, (2019) reported that the higher the parameters (depth of cut, feed rate, etc.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Chemotaxis Microfluidic Device Mould Using Digital Light Processing 3D Printing Method

Jemy,

Saptaji,

Triawan

et al. 2023

KEM

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Chemotaxis microfluidic devices are one type of lab-on-a-chip (LOC) devices that functions to minimize the volume of sample used and the testing time by conducting an analysis on a smaller scale. Chemotaxis microfluidic devices consist of micro-scale features that are delicate to be produced using conventional manufacturing methods. Chemotaxis microfluidic devices are generally manufactured using soft lithography. This study attempts to apply hot embossing process to replace soft lithography process, in which the hot embossing mould was fabricated using 3D printing, especially digital light processing (DLP) methods. This project investigates the challenges of fabricating the hot embossing mould of chemotaxis microfluidic device using DLP 3D printing. Three printed orientations for the moulds were produced and compared. The three moulds are subsequently used in the hot embossing process to produce chemotaxis microfluidic devices on poly(methyl methacrylate) (PMMA) substrate. The performance of the moulds is compared to the mould produced by micro-milling process using qualitative (visual analysis) and quantitative (dimensional analysis) methods. The analysis shows that DLP 3D printed moulds have comparable quality with those produced by micro-milling. The printing orientation has significant effect on the dimensional differences between the mould and design with mould WT (area of width and thickness attached to the platform) has the smallest dimensional differences.

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“…In milling, the contact area of tool flank surface and the machined surface changes due to time-varying tool wear, which generates process damping effect caused by violent extrusion between flank surface and machined surface, and process damping effect has been proved to be positively correlated with the wear width of tool flank and machining system stability [18,19].…”

Section: Introductionmentioning

confidence: 99%

Investigation of tool flank wear effect on system stability prediction in the milling of Ti-6AI-4 V thin-walled workpiece

Zhang

Zhao

et al. 2022

Int J Adv Manuf Technol

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Excessive tool wear can shorten tool life and cause low machining surface quality and efficiency in milling of Ti-6AI-4V thin-walled workpieces. To overcome the effect of time-varying tool flank wear on system stability prediction ignored by conventional method, a system stability prediction model considering tool flank wear effect in milling of Ti-6AI-4V thin-walled workpiece is proposed. In this work, the tool flank wear region is discretized into differential elements, then, the friction effect and process damping effect caused by extruding function between tool and workpiece are analyzed, and a time-varying milling force model is established.In this process, the relationship of cutting tool flank wear band width VB and section radius difference NB is determined, and the indentation volume between tool and workpiece is iteratively calculated, which is used to investigate process damping. After, time-varying milling force coefficients are derived considering different tool flank wear status. Then, in modal space, the evolutionary process of stability lobe diagrams considering tool flank wear effect is determined. Subsequently, to effectively predict system stability, tool flank wear curves and dynamic cutting force coefficients are calibrated by slot milling, and cutting force prediction values considering tool flank wear effect and experimental values in feed direction and normal direction are 7.3% and 12.1%, respectively. Finally, a series of machining tests are conducted to verify the effectiveness of tool flank wear on machining stability in milling of Ti-6AI-4V thin-walled workpieces to some extent, and the experimental results show that the system stability prediction accuracy of the proposed method is improved by 23.8% compared with that using conventional method.

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Radial depth of cut stability lobe diagrams with process damping effects

Cited by 22 publications

References 20 publications

Precision micro-milling process: state of the art

Precision micro-milling process: state of the art

Fabrication of Chemotaxis Microfluidic Device Mould Using Digital Light Processing 3D Printing Method

Investigation of tool flank wear effect on system stability prediction in the milling of Ti-6AI-4 V thin-walled workpiece

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